gradall crawler vendor service manual

XL SERIES CRAWLERMAINTENANCE MANUAL

Form No. 29635Original Issue 3/97Rev. 9/00

IntroductionNomenclatureTrack AdjustmentShoe Contact with Rock GuardCrawler Travel SpeedCrawler TrackingTrack ChainTrack RollersIdler Roller with Track Tension andAdjuster ComponentsDrive SprocketMiscellaneous

“High Pressure” denotes 10,000 psi gauge“Low Pressure” denotes 1,000 psi gauge

MAINTENANCE MANUALXL SERIES CRAWLER UNDERCARRIAGE

Table of Contents Page

Form No. 29635 3/47

I.II.III.IV.V.VI.VII.VIII.

IX.X.

NOTE!

(ii)13567815

192426

MAINTENANCE MANUALXL CRAWLER UNDERCARRIAGE(i)

Orientation:Right, left, front and rear relate to the direction of a person sitting in the upperstructure cab. The front of themachine is the idler roller end. The excavating (working) function should always be performed over the frontto minimize track component wear.

Related Materials:Other manuals related to your machine should be reviewed for information about a specific subjectother than XL CRAWLER UNDERCARRIAGE maintenance.

Other manuals available for your machine:Operator’s ManualService ManualSafety ManualSales LiteratureParts ManualBrochuresMiscellaneous Vendor Manuals covering specific components

Introduction

Form No. 29635 3/97 (ii)

This Manual covers technical repair and maintenance information for the CRAWLER UNDERCARRIAGE of theXL SERIES GRADALL

Charts showing component dimensions, part numbers, wear percentage, fastener torque values, hydraulichose and fitting torque values and lubrication capacity information are included.

Information about track chain adjustment, repair and replacement is also supplied.

This Manual does not cover machine operation or the hydraulic system. Refer to appropriate manuals forthat information.

Familiarize yourself with this Manual and its contents. Should you have questions concerning informationsupplied or a specific machine, please contact your GRADALL distributor for assistance.

Introduction (continued)

The following symbols are used to call your attention to safety notices.

DANGER: This symbol indicates an extreme hazard which could result in highprobability of death.

WARNING: This symbol indicates a hazard which could result in death orserious injury if proper precautions are not taken.

CAUTION: This symbol indicates a hazard which could result in injury ordamage to equipment or property if proper precautions are not taken.

DAILY:Read and adhere to all safety notices placed on the machine and in the various technical and operator’s manuals.Clean the machine as required.Be sure all grab handles, steps, and walking areas are clean and clear.Be sure the fire extinguisher works.Check that all safety decals are in place as when the machine was received new.Be sure all safety and operator’s manuals are with the machine.Report any safety hazard to the correct personnel.DO NOT operate the machine in an unsafe manner.DO NOT operate the machine if you are unfamiliar with the controls.DO NOT operate the machine if you are under the influence of alcohol or drugs.Be certain controller shut-off safety switch functions properly when the operator’s seat handle is raised.

DO NOT remove track tensioning hydraulic cylinder fitting while it is pressurized. Relievepressure by loosening the fitting one or two turns until grease escapes through the ventslot and pressure is relieved. Refer to the warning decal on the inside of the side framecover protecting the track tensioning device.

Safety

Form No. 29635 3/97 MAINTENANCE MANUALXL SERIES CRAWLER UNDERCARRIAGE(iii)

DANGER

WARNING

CAUTION

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WARNING!

This Manual covers the undercarriage mechanical running gear. Components such as planetary drive, hydraulicdrive motor and crawler brakes are not covered. Refer to the respective manual for information on thesecomponents. The undercarriage frame (carbody and side frame) is only covered in welding repairs.

A quick reference chart is supplied as an aid to find major components in their respective parts manual.

Refer to the contents page for specific components covered in this Manual.

How to extend Undercarriage life

l Dig only with the attachment over the idler end of the tracks. This gives even pin and bushingcontact, reducing wear. An attachment working over the sprockets will result in overloading thesurfaces between the sprocket and track bushing.

l Travel in the forward position with the sprockets at the rear end of the machine. Travelling in reverse causesexcessive wear on the sprockets and chains.

l When turning, utilize both tracks. Using power to one track only causes the opposite track to drag,wearing components more rapidly.

l Keep back and drive components clean and free of mud and debris.

I. Nomenclature

Form No. 29635 3/97

FIGURE 1GRADALL CRAWLER UNDERCARRIAGE

MAINTENANCE MANUALXL SERIES CRAWLER UNDERCARRIAGE1

l Perform daily inspections, checking for loose bolts, leaking seals, structural damage, correct track adjustmentand any abnormal wear. Report problem areas to appropriate personnel.

l Operate the machine in a smooth professional manner, especially over obstacles or rough terrain. This willusually prevent premature roller and component wear and reduce the possibility of track shoe bending.

l Always park the machine on level ground. If parked on an incline or uneven terrain, the roller seals couldbecome deformed or damaged resulting in lubricant loss. Without lubricant the internal parts of a roller willbe destroyed within hours.

l Keep the machine lubricated per lube chart.

l Replace or rebuild track chain components as required. Refer to the “Track Chain” section of this Manual forspecific component information.

l Keep a supply of metric fasteners in stock to replace broken or lost components.

l When replacing bolts, nuts, hydraulic hoses and/or hydraulic fittings, torque them to the values shown in thetorque charts on pages 28-30 of this Manual.

I. Nomenclature (continued)

Form No. 29635 3/97 2

Proper track adjustment is achieved when the link assembly is properly tensioned. This condition is reachedwhen the maximum sag between the top carrier roller and the drive sprocket matches the dimension “A”shown on Figure 2. The allowable sag for your machine is as follows:

XL 5200-35mm-1.375 in.XL 4200-35mm-1.375 in.XL 2200-20mm-0.781 in.

Track Adjustment Procedures:Clean track components so foreign material does not obstruct the tensioning assemblyfrom full free movement.

Install a straight edge on the track and measure sag per Figure 2 .

If tightening adjustment is required, add grease to the tensioning cylinder until the properdimension “A” in Figure 2 is achieved.

TO ADD GREASE TO THE TENSIONING CYLINDER, PROCEED AS FOLLOWS:

II. Track Adjustment

FIGURE 2TRACK ADJUSTMENT CHECK

Form No. 29635 3/97MAINTENANCE MANUALXL SERIES CRAWLER UNDERCARRIAGE

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Remove the track tensioning device cover from the side frame. See Figure 3. Follow the warning decalinstructions on the inside of the cover. See Figure 4.

FIGURE 3SIDE FRAME TRACK TENSIONING DEVICE COVER

FIGURE 4WARNING DECAL

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3

Attach the button head hydraulic fitting (furnished in the tool kit) to the fill valve that is screwedinto the tensioning cylinder. See Figure 5 and Figure 6.

NOTE! The XL 5200 also has a relief valve installed in the tensioning cylinder.

Pressurize the cylinder until the proper dimension “A” is achieved. See Figure 2.

Reinstall the track tensioning device cover to the side frame. See Figure 3.

IF THE TRACK TENSION IS TOO TIGHT AND NEEDS LOOSENING PROCEED AS FOLLOWS:

Remove the track tensioning device cover from the side frame. See Figure 3. Follow the warning decalinstructions on the inside of the cover. See Figure 4.

Carefully back out the hydraulic fill valve from the tensioning cylinder until lube starts to escapefrom the relief slot machined in the threads. See Figure 5 and Figure 6.

Release the amount of lube necessary to achieve proper dimension “A” in Figure 2 for your machine.

II. Track Adjustment (continued)

FIGURE 5BUTTON HEAD HYDRAULIC FITTING

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FIGURE 6FILL VALVE (TRACK TENSIONING CYLINDER)

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FIGURE 7TENSIONING CYLINDER FILL VALVE WITHBUTTON HEAD FITTING

FIGURE 8FILL VALVE AND BUTTON HEAD FITTING INSTALLEDIN TENSIONING CYLINDER

Figure 7 and Figure 8 show the tensioning cylinder fill valve and the button head fittingthat fits to it. Be certain you understand how to install the buttonhead fitting to the fillvalve (one-way check valve) before attempting adjustment.

Reinstall the side frame cover.

Do not remove any parts until all pressure in the tensioning cylinder has been relieved. Seriousinjury could occur. Refer to the decal on the undercarriage side frame tensioning cylinder cover.

NOTE!

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WARNING

Form No. 29635 3/97

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Improper Adjustment Hazards:TRACKS TOO TIGHT:If track is too tight, excessive friction will cause a reduction in machine performance and may causeaccelerated wear of rolling track components.

TRACKS TOO LOOSE:If track is too loose, component service life is drastically reduced. Loose tracks easily become mis-aligned andmay jump off the sprockets when the machine is turned. A loose track may also jump sprocket teethcausingdamage or premature wear. At best, loose tracks make it difficult to travel in a straight line.

NOTE! Both tracks must be adjusted equally to ensure proper travel performance.

II. Track Adjustment (continued)

Contact with the rock guard may result in wear on a portion of the leading edge. The track chain may flex upbetween rollers as the machine travels over the ground. The amount that the chain can flex in this direction isincreased when internal pin and bushing wear occurs. As the chain flexes up, the leading edge of the shoe maycontact the rock guard. (See Figure 9) . Also, rail and track roller tread wear reduces the clearance between thetrack shoes and the rock guards. This would increase the possibility of contact. Normal contact may also occur ifthe track chain is tipped up on one side by rough terrain.

This type of wear does not affect the function of the track shoe and, therefore, is a minor wear pattern. It does,however, reduce the bending strength of the shoe.

FIGURE 9SHOE CONTACT WITH ROCK GUARD

III. Shoe Contact with Rock Guard

Form No. 29635 3/97 MAINTENANCE MANUAL

XL SERIES CRAWLER UNDERCARRIAGE5

Adjustment for crawler undercarriage travel speed is performed of the control valves. See Figure 10. Thereare stroke limiters provided on each crawler propel valve end cap. Use the following tests to set free-running speed and actual travel speed. A stopwatch and point (for marking the tracks) will be requiredfor these tests.

Before checking travel speed, be certain the tracks, chains, and rollers are free of mud, and otherdebris that could interfere with achieving correct test results. Check track tension before testing travel speed. Iftrack tension is not correct, perform track adjustment procedures outlined on pages 3 and 4 of this Manual.

Travel Speed Testing and Adjustment Procedures:

Rotate the upperstructure so the boom is perpendicular to the right-hand track. Place the bucket on the groundwith the boom extended. Apply down pressure to the boom to raise the right hand track off the ground. Paint astripe on the track to be used as a reference point.

Set the crawler speed to “High”. Push the right-hand forward travel pedal. When the paint stripe reaches yourdesired location, start the stopwatch and time the track for one complete revolution. The correct speed is asfollows: XL 5200: 8.6 to 9 seconds (27.9 RPM sprocket speed). XL 4200: 7.8 to 8.2 seconds (27.9 RPM sprocketspeed). XL 2200: 3.9 to 4.3 seconds (55.7 RPM sprocket speed).

If travel speed needs corrected, remove the plug from the rear stroke limiter. Insert an allen wrench in the strokelimiter screw. Loosen the stroke limiter housing and adjust it to achieve the correct travel speed. Turning thestroke limiter screw clockwise decreases travel speed, turning it counter clockwise increases travel speed. Re-testtravel speed after adjustment. See Figure 10.

Repeat test for right-hand reverse travel using the front stroke limiter. After this travel speed is set, carefully raisethe boom to lower the right hand track to the ground.

Rotate the upperstructure so the boom is perpendicular to left-hand track. Repeat forward and reverse trackspeed test for the left hand track using steps 1 thru 4.

After free-running speed has been checked, mark off a level, linear distance of 100 feet. Set the crawler under-carriage for high speed and enter the 100-foot marked course travelling straight and at full travel speedforward. Begin timing as the machine enters the course and end timing when it exits. Correct travel speed is asfollows: XL 5200: 30.3-30.9 seconds. XL 4200: 27.8-28.4 seconds. XL 2200: 19.5-20.1 seconds.

If travel speed is slower than the above times and free-running speed was tested correctly, donot increase track speed to achieve the above times. Use free-running speed as the maximum speedfor the crawler undercarriage.

Repeat step 6 for reverse travel.

IV. Crawler Travel Speed

NOTE!

Form No. 29635 3/97 6

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Crawler Undercarriage TrackingThe crawler undercarriage is allowed a small deviation from straight travel. If this deviation is excessive,it can be adjusted using the crawler propel valve stroke limiters. Whenever tracking is adjusted, the free-running travel speed of the undercarriage must be checked to ensure it does not exceed specificationsfor the model being tested. It may be necessary to slow one track, rather than speed up the other.

To Check Undercarriage Tracking Proceed as Follows:Mark off a level, linear distance of 100 feet. Set the crawler undercarriage for “High” speed. Enter the 100-footmarked-off course straight and at full travel speed forward.

After completing the course, measure the machine’s path of travel for deviation from a straight line. Maximumallowable deviation is 10 feet. If free-running speed has been checked and is correct, it is best to slow the fasttrack when adjusting tracking. The stroke limiter adjustment screw should not be adjusted more than 1/8 of aturn before retesting. The stroke limiter adjustment is very sensitive. Use the rear stroke limiter to adjust forwardtravel.

After forward travel tracking test is complete, repeat for reverse travel. Use the front stroke limiter to adjust forreverse travel. See Figure 10.

IV. Crawler Travel Speed (continued)

V. Crawler Tracking

Form No. 29635 3/97

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FIGURE 10CRAWLER SPEED ADJUSTMENTS

The track chain assembly known in the industry consists of a series of links, pins and bushings on which the trackshoes are bolted. The chain contacts the drive sprocket on one end of the machine and the idler roller chaintensioning assembly on the other end. As the sprocket turns, the teeth contact the bushings pulling them aroundthe circumference resulting in machine travel.

The links are fastened together by pins and bushings which are sealed. See Figure 11 and Figure 18.The chain must be installed with the pin end of the links facing the back of the machine at ground level.

To split open a track, first locate the master pin. It has a (machined center) countersink in the center of each end.See Figure 18. Then position the track so it is accessible. Use a portable press to push the pin out. The chain isnow broken apart and both ends are free.

Stay clear of the end of the chain to prevent injury should it roll uncontrolled to theground. We recommend you use a “come-a-long” or similar fastening device to lower theend of the chain to the ground.

Reverse the procedure for reassembly.

VI. Track Chain

FIGURE 11TRACK PIN & BUSHING

WARNING

Form No. 29635 3/97

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The accumulated operating (traveling) hours on the machine result in link wear. Replace whenever the 100%value is reached. Allowable link wear is per Table 1:

FIGURE 12TRACK LINK

VI. Track Chain (continued)

TABLE 1TRACK LINK WEAR PERCENTAGE DATA



Track ShoesThe standard track shoes (pads) used on the GRADAlL crawler machines are the triple grouser type. Thisdesign gives a lower penetration into the surface, reduces turning resistance, improves maneuverabilityand reduces loads on other undercarriage parts.

Other style track shoes are also available.

To minimize shoe bending or breaking, do not use a wider shoe than is required. It is important to keepthe track bolts properly torqued. (Refer to bolt torque chart on pages 28-30 of this Manual)Approximately every 100 hours the bolt torque should be checked. Visually check for loose or missing boltsat the start of each operating shift. If track shoes show a tendency to bend or break, the shoes may be toowide for the working surface.

Maximum back shoe wear of 100% (See Table 2 for values applicable to your machine) isallowable if the machine is normally working on medium soft ground. Operating on rocky ground theshoes must be replaced when the wear is 75%. (Second column from right, Table 2. )

FIGURE 13TRIPLE GROUSER SHOES

TABLE 2TRIPLE GROUSER SHOE WEAR PERCENTAGE DATA


Form No. 29635 3/97 10

Track PinThe hardened (surface hardness Rc 60) track pin is pressed into the right and left link of the chain. It is alsoinstalled through the bushing at each end of the link. There are seals at each end to prevent contamination.

The outside diameter (O.D.) of the pin wears against the inside diameter (I.D.) of the bushing with which it ismaking contact. See Figure 14.

For allowable track chain wear tolerances, see “When to Repair Track Groups,” Figure 19 and Table 4.Once the pin reaches the allowable wear limit it may be rotated 180 degrees for extended life. See Figure 15.

FIGURE 14TRACK PIN


Form No. 29635 3/97 MAINTENANCE MANUAL XL SERIES CRAWLER UNDERCARRIAGE11

FIGURE 15TRACK PIN TURNING

Track BushingThe track bushings fit into the counterbore of each link. There is one bushing per link set. The track pin fitsthrough the bushing.

The O.D. of the bushing contacts the teeth of the drive sprocket during travel. This results in bushing wear atthe sprocket side only. This wear along with pin wear is a major factor in causing looseness and damage tothe chain by increasing pitch length.

Outside wear of the bushings is of three types: Radial Wear, Forward Drive Side Wear, and Reverse Drive SideWear. (See Figure 16) Measurements should be taken at each position; use the one which indicatesmaximum wear. (Refer to Table 3).

FIGURE 16TRACK BUSHING WEAR


TABLE 3OUTSIDE BUSHING WEAR

Form No. 29635 3/97 12

Master Pin and BushingA master pin and bushing is used on each track. These components are the ones used to take the track apart andput it together. See Figure 17. The master pin and bushing wear more rapidly than do other pins andbushings. This is because the bushing does not extend into the counterbore of the link.

The master pin can be identified by the countersink (center) machined in the center of each end.

A portable press is used to remove the master pin.

Once the master pin is removed, the track may roll uncontrolled to the ground. To avoidinjury, stay clear.WARNING!

FIGURE 17MASTER PIN


MACHINE CENTER(COUNTERSINK)

FIGURE 18TRACK PIN SEALS

The track chain link is sealed at each end of the track pin. This design helps guard against contaminants, a majorsource of premature wear. The seals must be installed. See Figure 18.

When the pins and bushings are assembled they must be well lubricated.

Track BoltsThe track bolts have special wear-resistant heads, self-locking, square nuts and rolled threads. These bolts meetAmerican standard Grade 8 and European standard 12.9 class.

Torque values are found in the torque chart. See Pages 28-30.

The bolts should be randomly checked for torque approximately every 100 hours. Check for loose or missing bolts atthe start of each operating shift.



When To Repair Track GroupOnce you determine exactly when to replace each worn part of your undercarriage, you have maximized youropportunity to exact the most economical use of your undercarriage.

This Manual contains tables showing the maximum wear limit for each track moving part. If these limits areobserved, you will realize economical performance without costly expenses resulting from componentdamage, replacement parts and machine downtime.

For measurement of component wear, a few simple tools are needed: flexible tape, small caliper, large caliper,depth gauge, steel ruler and straight edge.

Links, Pin and Bushing Wear MeasurementTo establish the average wear measurement, choose a length of 4 sections of link assembly on top of theundercarriage in a well tensioned zone. Do not include master pin and link in the four sections of linkmeasured. See Figure 19 and Table 4.

Once the wear measurement reaches the 100% limit the pins may be turned 180 for extended life. If thisoperation has been previously performed the worn parts must be replaced.

FIGURE 19FOUR SECTIONS OF THE LINK ASSEMBLY


TABLE 4WEAR DATA: 4 SECTIONS OF THE LINK ASSEMBLY

Form No. 29635 3/97 14

FIGURE 20TRACK ROLLER

VII. Track Rollers


The track rollers used on the XL SERIES GRADAlL CRAWLER are sealed units that normally require no resealingor refilling (unless they have been damaged). The rollers are filled with SAE 30 or SAE 40 weight oil. To fillthe roller, remove the fill plug from the body and fill with the quantity of oil shown for your machine inTable 5.

The XL 5000 and XL 4000 use the bottom roller design for the top and bottom of the track. The XL 2200uses a bottom design on the bottom of the track and a carrier design roller for the top of the track. Referto the quick reference chart or the applicable parts manual for part number identification.

TABLE 5TRACK ROLLER LUBE CAPACITY CHART

Roller SealsIf the seal group is being replaced, use new parts only. Used seals will most likely fail shortly after rebuild.Installation procedure for roller seals is as follows:

The mating surface where the seals contact must be dry and clean, free of dirt, nicks and burrs.

Install O-ring on the roller shaft.

Install the seal group into the roller shell seat. Remove the plastic band holding the rings together.

Press the collar onto the roller shaft and lock in place with the dowel.

Invert the roller assembly and perform steps 1 through 4.

Fill roller with lube. See Table 5.

FIGURE 21ROLLER SEALS

VII. Track Rollers (continued)

Form No. 2963516

1.2.

3.4.5.

6.

Track Roller Disassembly (See Figure 21)

Remove lube fill plug and dump lube into a container.

Press dowel pin out of collar.

Remove seals and shaft.

Press out bushings.

Track Roller Assembly (See Figure 21)

Install bushings into roller shell.

Install collar to roller shaft.

Install dowel pin through collar and shaft.

Install O-ring in roller shaft.

Install seal group in roller shell seal seat.

Insert collar and shaft into shell until collar bottoms to the seal group.

Invert roller 180.

Complete component assembly as in steps 2 through 6.

Fill Roller with lube. See table 5.


Form No. 29635 3/97E MAINTENANCE MANUAL XL SERIES CRAWLER UNDERCARRIAGE17

1.2.3.4.

1.2.3.4.5.6.7.8.9.


Form No. 29635 3/97 18

Bottom and Carrier Track RollersThe rail diameter of the bottom and carrier roller for your machine when it was new is shown in Table 6 andTable 7. Whenever the wear percentage reaches the 75% range the roller diameter should be resurfaced to sizeor the roller replaced.

The track roller rail surface hardness is Rc 55.

FIGURE 22BOTTOM ROLLER

FIGURE 23CARRIER ROLLER XL 2200

TABLE 6BOTTOM ROLLER WEAR PERCENTAGE DATA

TABLE 7CARRIER ROLLER WEAR PERCENTAGE

VIII. Idler Roller with Track Tension and Adjuster Compartments


FIGURE 24IDlER ROLLER:TYPICAL

The idler roller assembly is located at the front of each side frame. Major components are Idler Roller,Tensioning Spring, Hydraulic Adjusting Cylinder, Idler Slides and Connecting Bracket.

This assembly acts as a shock absorber for the track system. It compensates for shock loads (caused bylarge rocks, uneven terrain, etc.) imposed by momentarily adjusting the chain pitch. Compensation is accomplishedby the tensioning spring and hydraulic cylinder collapsing the required amount, thus minimizing the chanceof chain breakage.

The XL 5200 hydraulic adjusting cylinder is equipped with a relief valve to assist in accepting majorshock loads that could be imposed on this size machine. The relief valve will relieve lubrication tocompensate for excessive shock loads. Should this occur very often it may be necessary to rechargethe cylinder with lubricant once the travel cycle returns to normal.

FIGURE 25IDLER ROLLER

The idler roller has two outside rails which is the area that the track links make contact. These rails arehardened to Rc 55.

The rollers are “lifetime” lubricated and under normal working conditions no further lubrication maintenanceis required. The idlers should be randomly checked while working to protect against destruction should aseal be damaged.

To install lubrication we recommend the use of a low pressure pump with a nozzle on the end that will fitthrough the fill hole in the idler body. Use SAE 30 or SAE 40 oil at capacities for your machine. See Table 8.

TABLE 8IDLER ROLLER LUBRICANT CAPACITY

Form No. 29635 3/97

VIII. Idler Roller with Track Tension and Adjuster Components(cont.)

20

Idler Roller Disassembly (See Figure 25)

ASSUMPTION: RECOIL COMPONENTS HAVE BEEN REMOVED AND THE ROLLER IS FREE.

Remove one of the dowel pins that fasten the bracket to the shaft.

Remove the remaining components which are now free of the shaft.

Press out the bushing. (The bushing can only be removed by use of a vertical press with correct tooling.)

If necessary, remove the remaining dowel pins and bracket.

Idler Roller Assembly (See Figure 25)

Press the bushings into the idler shell.

Mount a bracket on to the shaft.

Insert seal group into the idler shell seal seat.

Install O-ring on the shaft.

Insert the complete sub assembly in the idler shell to the point where it bottoms the seal group.

Invert the idler and assemble components as in steps 1 through 4.

After loose assembly press tightly together using a vertical press.

NOTE! The seal group is assembled the same as in the bottom rollers. See Figure 21.

Idler Roller and Track Tensioner Removal and Replacement to the Side Frame

Serious injury could result if the pressure is not relieved from the tensioner and recoil system.See decal on the side frame cover and “Track Adjustment” section of this Manual.

To remove pressure from the cylinder, carefully back off one or two turns on the fill fitting. (Refer to TrackAdjustment section of this Manual.) As soon as lube starts to come out the vent hole STOP backing off thefitting. Once pressure is relieved it is safe to remove the roller and tensioner assembly.

It will be necessary to collapse the tensioning cylinder fully for reassembly of the group.

See Table 9 for the part number and stroke of the cylinder for your particular machine.

TABLE 9IDLER ROLLER TENSION CYLINDER

Form No. 29635 3/97

VIII. Idler Roller with Track Tension and Adjuster Components (cont.)

WARNING


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Track Tension and Idler Roller Disassembly (See Figure 24)

Relieve all pressure from the track tensioning cylinder. See Figure 3 and Figure 4.

Carefully separate the track chain and lay it on the ground.

Remove the recoil device group (refer to the correct page in the Parts Manual for your machine).

Remove the track tension group (refer to the correct page in the Parts Manual for your machine).

Remove the two (slide brackets) support groups and idler pin from the side frame.

Remove idler roller from the machine.

Examine all fasteners and seals for damage. Replace any damaged component.

Track Tension and Idler Roller Reassembly

Clean, lubricate, and check all components for damage.

Reassemble idler roller with support group and fork and install into side frame (refer to PartsManual for parts required).

Install track tension group (refer to Parts Manual for parts required).

Torque all fasteners to correct value.

Reassemble track chain to side frame and lack master pin and bushing as required.

Using button head coupling (8381-3109) supplied in the GRADALL Tool Kit, pressurize the tensioningcylinder to achieve the correct track adjustment. (Refer to Track Adjustment section of this Manual.)

Install cover over the opening in the side frame for the valve that is used for the tensioning cylinder adjustment.

Check that the “WARNING” for track adjustment is in place. If it is not on the inside of the side frame cover,(installed at step 7) or is illegible, notify the correct personnel to have it replaced immediately.

Form No. 29635 3/97

VIII. Idler Roller with Track Tension and Adjuster Compartment (cont.)

1.2.3.4.5.6.7.

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3.4.5.6.

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Idler Roller Rail Weld Refacing

TABLE 10WEAR PERCENTAGE DATA

Figure 26 and Table 10 show the allowable wear on the rail height of the idler roller. A good undercarriage shophas the ability to rebuild (reweld) the roller to its original dimensions. When wear percentage reaches 100% theidler roller must be rebuilt or replaced.

FIGURE 26FRONT IDLERS

Form No. 29635 3/97

VIII. Idler Roller with Track Tension and Adjuster Components (cont.)


The drive sprocket is sized to provide proper travel performance for the model machine on which it is used. It isbolted to a gear box that is also sized for correct performance. The drive sprocket always has an uneven numberof teeth. As they rotate the drive chain is engaged which results in machine travel.

The six major types of drive sprocket wear are:

Drive Chain Wear --- when operating forward.

Reverse Drive Side Wear --- when operating in reverse.

Climbing Wear --- result of increased track pitch.

Root Wear --- when bushings slide from side to side.

Rotative Wear --- when bushings rotate as they leave (forward) or enter (reverse) the sprocket.Reverse Drive Side Tip Wear --- when sprocket pitch is greater than track pitch.

The drive sprocket is cast of special manganese steel hardened to Rc 55. If it is reconditioned by welding it mustconform to the dimensions of a new sprocket.

Table 11 gives the new and allowable wear tolerances of the sprocket on your machine.

TABLE 11NEW DRIVE SPROCKET DIMENSIONS

FIGURE 27DRIVE SPROCKET

Form No. 29635 3/97

IX. Drive Sprocket

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Wear on the sprocket is very difficult to measure. As the machine works, wear takes place in such a way thatno trace of the original teeth are left for use as a measuring point. Sprockets should be rebuilt or replacedwhenever wear percentage reaches 100%.

`Wear is never uniform, so measurements should be taken at different points on the sprocket teeth. See Figure 18.Use the area showing the most wear as your gauge for determining wear percentage on Table 12.Dimension “0F” from Table 11 is the original diameter of your respective sprocket. Dimension “0G” is thedimension to the centerline of the bushing for your back as it lays against the root of the sprocket toothwhen new.

TABLE 12DRIVE SPROCKET WEAR PERCENTAGE

FIGURE 28TOOTH DEPTH

Drive Sprocket Removal from Drive MechanismTo remove the drive sprocket from the machine, proceed as follows:Release pressure from the track tensioning device per safety decal instructions (Refer to trackAdjustment section of this Manual.)

Separate the track chain at the master pin and bushing. See Figure 17.

Carefully lay the drive chain on the ground. Use good SAFETY practices to prevent injuries.

Attach lifting or holding device to the sprocket to prevent uncontrolled falling once it is free of the machine.

Remove the socket head capscrews holding the weldment to the planetary drive.

Lift the sprocket to the work area as required.

Form No. 29635 3/97

IX. Drive Sprocket (continued)

MAINTENANCE MANUALXL SERIES CRAWLER UNDERCARRIAGE

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IX. Drive Sprocket (continued)

Drive Sprocket Reassembly to Drive MechanismTo reassemble the drive sprocket, proceed as follows:

Clean all areas of the side frame and drive mechanism where the sprocket fits.

Use “Never-seez” on mounting surfaces (pilots).

Lift drive sprocket into place (pilot mounting surface).

Install mounting capscrews (socket head metric).

Torque mounting screws to correct value as required. Refer to Table 13 and 14.

Lift track chain in place and fasten together at the master pin and bushing.

Adjust the track chain to correct specifications.

X. MiscellaneousTowingIf power is lost to the crawler drive and it becomes necessary to tow the unit proceed as follows:

Remove the sheetmetal guards from the drive mechanism as required for access to the planetary drive.

Remove the planetary drive cover mounting socket head capscrews and store in a safe place for reuse.

Remove the sun gear from the planetary drive and store in a safe place for later reuse.

Reinstall the planetary drive cover.

Perform steps 1 through 4 on the opposite track.

Install towing chain and/or cable to towing area on the carbody.

Carefully tow the machine to the area designated.

When the machine is to be put back into service, it will be necessary to reinstall the removed sun gear to theplanetary drive. Retorque fasteners to correct value per the torque chart. Reinstall any sheetmetal protectivecovers removed. Lubricate the machine per specifications before resuming normal operations.

Undercarriage (Carbody and Side Frames)The undercarriage (carbody and side frames) of the GRADALL CRAWLER is designed correctly for the size machineit is mounted under. The integrity of the design is assured during manufacture by the use of intricately designedwelding and machining fixtures.

Welding RepairsShould welding repairs be required, adhere to the following procedures:

Disconnect the battery leads to prevent electrical component damage.

Position the ground clamp adjacent to the area being welded. This will prevent arcing between components suchas bearings, etc. which could cause damage to them. Do not ground through rotating parts.

Use welding rod or wire conforming to AWS 7018 low hydrogen process.

Form No. 29635 3/97

1.2.3.4.5.6.7.

1.2.3.4.5.6.7.

1.2.

3.

26

Piston MotorA bent axis piston type motor is fastened to the planetary drive at the sprocket end of the side frame. It can beshifted from low speed to high speed or vice versa as required. Refer to the Crawler Hydraulic Schematic andthe Vendor Service Manual for more detail.

Planetary Drive and Crawler Holding BrakeA planetary gear reduction box and disc brake assembly is connected to the drive sprocket. The brake isnormally set. It is released by hydraulic pressure whenever the travel cycle is activated and remainsdisengaged as long as the travel circuit is pressurized. The brake is not a dynamic stopping brake. It is a holdingbrake only.

Track GuidesThe function of the track guides bolted to the side frame is to keep the track chain in line. It also may keep thetrack chain from jumping the sprockets when turning if the chain pitch is outside the allowable tolerances.

Planetary Drive and Crawler Holding Brake (continued)The planetary gear box operation is explained in a separate Manual supplied by the Vendor. Refer to thatmanual for information on the function of this assembly. Refer to the lubrication chart for the type and capacityof the gear box.

Bolt Torque ChartsThe following bolt torque charts (Table 13 and 14) covering English and Metric fasteners are the ones used byGRADALL Ratings are for lubricated fasteners. Do not exceed the allowable rating. An overtorqued bolt in mostcases will fail as rapidly as an undertorqued one. Bolt sizes and torque values are shown in most cases with thedescription given in the GRADALL Parts Manual.

To check GRADALL torque values, set the torque wrench at the minimum rated torque value andtighten fastener. If the torque wrench releases before the fastener moves, assume that the fastenertorque is correct.

Form No. 29635 3/97

X. Miscellaneous (continued)

NOTE!


TABLE 13BOLT TORQUE VALUES FOR METRIC FASTENERS

Form No. 29635 3/97


28

TABLE 14BOLT TORQUE VALUES AND TOLERANCES FOR LUBRICATED ENGLISH BOLTS

“Never-seez” to be used on master link pin before assembly torque pad bolts overmaster link to 185 ft. lb. +10 -0

Form No. 29635 3/97


NOTE!


Hydraulic Hose and Hose Fitting Torque ChartsTo minimize leakage, the hydraulic hoses and hydraulic hose fittings are torqued to specified values. Whenever ahose or fitting is removed, it should be retorqued to the correct value when it is replaced. Refer to the hydraulichose and hydraulic fitting torque charts (Table 15, Table 16 and Table 17) for correct values used on theGRADALL product line.

TABLE 15

*Torque values with an asterisk are from JIC Fitting Torque Chart.

TABLE 17ORS FACE SEAL TUBE/HOSE TO FITTING

Form No. 29635 3/97


TABLE 16

30

ToolsStandard heavy equipment maintenance tools are required to work on the GRADALL XL SERIES CRAWLERUNDERCARRIAGE.

Torque wrenches capable of achieving rated fastener values, wrenches for metric bolts and English S.A.E. boltsmust be available.

Large and small calipers, straight edges, steel measuring tape and a depth gauge are required for componentwear measurement.

Miscellaneous tools such as “come-a-long”, large” “C” clamps, etc. may also be required for some repairs.

A grease fun and other tools GRADALL determines “unique” and necessary for good maintenance are furnishedin the tool kit supplied with each machine.

Form No. 29635 3/97


MAINTENANCE MANUAL XL SERIES CRAWLER UNDERCARRIAGE31

Linear Motion andAssembly Technologies ServicePneumaticsHydraulics

Electric Drives and Controls

Verstellpumpe A11VO/A11VLO Variable Pump A11VO/A11VLO Baureihe / Series 11NG / Size 190 – 260

RDE 92500-21-R/07.07

Reparaturanleitung / Repair ManualBaugruppen / Assembly Groups

R1

2/32 Bosch Rexroth AG Reparaturanleitung/Repair Manual A11VO / A11VLO RDE 92500-21-R/07.07

Vermeidung von Gefahren

Für einen sicheren Betrieb und um Schäden bei der Reparatur zu vermeiden, lesen Sie diese Reparaturanleitung sorgfältig und aufmerksam durch!

Für Personen- oder Maschinenschäden, die durch Nichtbe-achtung dieser Reparaturanleitung entstehen, verfällt jegliche Gewährleistung der Bosch Rexroth AG.

1 Zu dieser AnleitungDiese Anleitung unterstützt Sie bei der Reparatur und der Wiederinbetriebnahme von Rexroth A11VO/A11VLO Verstell-pumpen Diese Anleitung umfasst die folgenden Kapitel:

• „Sicherheit“ auf Seite 7

Hier erhalten Sie grundsätzliche Hinweise zum sicheren Umgang mit Verstellpumpen und zu deren Betrieb.

Lesen Sie dieses Kapitel, bevor Sie anfangen zu arbeiten.

• „Produktbeschreibung“ auf Seite 11

Hier erfahren Sie, wie Sie den Typ einer Verstellpumpe feststellen. Ferner fi nden Sie hier eine Übersicht über die Funktionsweise und Informationen zur bestimmungsgemäßen Verwendung der Pumpe

Lesen Sie dieses Kapitel, um Ihr Grundwissen über Verstell-pumpen aufzufrischen.

• „Austausch von Baugruppen“ auf Seite 15

Rexroth stellt verschieden Reparatursätze zur Verfügung. Dieses Kapitel erklärt Ihnen, wie Sie Dichtungen und Bau-gruppen einer Verstellpumpe austauschen.

• „Funktionsprüfungen“ auf Seite 25

Hier erfahren Sie, wie Sie die Funktion einer Rexroth A11V(L)O Verstellpumpe mit LRDS-Regler überprüfen können.

Avoiding Dangers

To ensure safe operations and avoid damages during repairs, read this repair manual carefully and attentively.

Bosch Rexroth AG accepts no responsibility for personal injuries or damages to the machine that arise from disregarding this repair manual.

1 About this ManualThis manual supports you in the repair, adjustment and recom-missioning of Rexroth A11VO/A11VLO variable pumps. The manual is structured as follows:

• “Safety” on page 7

This chapter provides you with basic hints and tips regarding working with and operating variable pumps.

Read this chapter before you start working.

• “Product Description” on page 11

This chapter explains how you identify the fvariable pump. Additionally, it provides you an overview about how the variable pump works and information regarding the correct usage.

Read this chapter to refresh your knowledge of the variable pumps.

• “Exchanging Subassemblies” on page 15

Rexroth provides various replacement parts for repairs. This section explains, how you exchange seals and components of a variable pump.

• “Functional Checks” on page 25

This chapter explains how you check the proper function of a Rexroth A11V(L)O variable pump with LRDS regulator.

Bosch Rexroth AGRDE 92500-21-R/07.07 Reparaturanleitung/Repair Manual A11VO / A11VLO 3/32

1.1 Inhalt

1 Zu dieser Anleitung 2

1.1 Inhalt 3

1.2 Gültigkeitsbereich dieser Anleitung 4

1.3 Wichtige Unterlagen 5

1.4 Gefahrenkennzeichnungen und Piktogramme 6

2 Sicherheit 7

2.1 Grundlegende Sicherheitshinweise 7

2.2 Anforderungen an das Personal 10

3 Produktbeschreibung 11

3.1 Typschild 11

3.2 Funktionsbeschreibung 11

3.3 Technische Daten 13

4 Austausch externer Baugruppen 15

4.1 Triebwelle abdichten 16

4.2 Reglergehäuse abdichten 19

4.3 Dichtungen austauschen 22

5 Funktionsprüfungen 25

5.1 Vorbereitungen 25

5.2 Prüfung des Load-Sensing Reglers (S) 26

5.3 Prüfung des Leistungsreglers (LR) 27

5.4 Prüfung des Druckreglers (D) 29

1.1 Content

1 About this Manual 2

1.1 Content 3

1.2 Validity of this Manual 4

1.3 Important Documents 5

1.4 Danger Labels and Pictograms 6

2 Safety 7

2.1 Basic Safety Information 7

2.2 Requirements on the Personnel 10

3 Product Description 11

3.1 Name Plate 11

3.2 Functional Description 11

3.3 Technical Data 13

4 Exchanging External Assembly Groups 15

4.1 Sealing the Drive Shaft 16

4.2 Sealing the Control Unit Housing 19

4.3 Replacing Seals 22

5 Functional Checks 25

5.1 Preparations 25

5.2 Checking the Load-Sensing Control (S) 26

5.3 Checking the Power Control (LR) 27

5.4 Checking the Pressure Control (D) 29


1.2 Gültigkeitsbereich dieser AnleitungDiese Reparaturanleitung gilt für die Verstellpumpen A11VO/A11VLO der Bosch Rexroth AG. Informationen zu zugelas-senen Druckfl üssigkeiten entnehmen Sie den Angaben des Anlagenherstellers.

Diese Reparaturanleitung richtet sich an folgende Zielgruppen:

• Anlagenbetreiber

• autorisierte Fachbetriebe bzw. Händler

• Anlagenhersteller

Für den Anlagenhersteller sind zusätzlich auch die jeweilige Einbauzeichnung, das technische Datenblatt, die Betriebsan-leitung und die Auftragsbestätigung der Bosch Rexroth AG verbindlich.

1.2 Validity of this Manual

This manual is valid for the Bosch Rexroth variable pumps A11VO/A11VLO. Refer to the system manufacturer for informa-tion about the allowed hydraulic fl uids.

This repair manual is directed at:

• the system operator

• authorized dealers

• the system manufacturer

For the system manufacturer, the installation drawing, the catalog sheet, the manual, and the confi rmation of order from the Bosch Rexroth AG are also obligatory.


1.3 Wichtige UnterlagenBevor Sie mit den in dieser Anleitung beschriebenen Arbeiten anfangen, stellen Sie sicher, dass Sie folgende Unterlagen griffbereit haben:

• Auftragsbestätigung

Die Auftragsbestätigung enthält die voreingestellten tech-nischen Daten. Die Verstellpumpe darf nur unter den in der Auftragsbestätigung angegebenen Werten und Bedingun-gen betrieben werden.

• Einbauzeichnung

Die Einbauzeichnung der Verstellpumpe enthält die Außen-abmessungen, sämtliche Anschlüsse und den Schaltplan.

• Technisches Datenblatt

Die technischen Datenblätter RD 92500 enthalten u. a. die zulässigen technischen Daten für die Verstellpumpen.

• Gesamtschaltplan der Maschine bzw. Anlage

Der Hydraulikschaltplan und der elektrische Schaltplan der Maschine bzw. Anlage enthalten die Informationen zu den hydraulischen bzw. elektrischen Anschlüssen. Diese Daten brauchen Sie, um mit der Verstellpumpe als Teil der Maschi-ne bzw. Anlage zu arbeiten. Die Unterlagen erhalten Sie vom Maschinen- bzw. Anlagenhersteller.

• RD 90300-B: Allgemeine Betriebsanleitung für Verstell-pumpen

Die allgemeine Betriebsanleitung unterstützt Sie bei Instal-lation, Inbetriebnahme und Betrieb von Rexroth-Verstellpum-pen.

• Produktspezifi sche Betriebsanleitung

Die produktspezifi sche Betriebsanleitung enthält spezielle, für die Verstellpumpe gültige Informationen. Informieren Sie sich bei Rexroth, ob es zu Ihrer Verstellpumpe eine produkt-spezifi sche Betriebsanleitung gibt.

Folgende Rexroth-Druckschriften geben Ihnen weitere Informa-tionen zu Installation und Betrieb der Verstellpumpe:

• RD 90220: Druckfl üssigkeiten auf Mineralölbasis

Diese Druckschrift beschreibt die Anforderungen an eine Druckfl üssigkeit auf Mineralölbasis für den Betrieb in Rex-roth-Verstellpumpen und unterstützt Sie bei der Wahl einer Druckfl üssigkeit für Ihre Anlage.

• RD 90221: Umweltfreundliche Druckfl üssigkeiten HEES, HEPG, HETG für Verstellpumpen

Diese Druckschrift beschreibt die Anforderungen an eine umweltfreundliche Druckfl üssigkeit für den Betrieb mit Rex-roth-Verstellpumpen und unterstützt Sie bei der Wahl einer Druckfl üssigkeit für Ihre Anlage.

• RD 90223: Verstellpumpen für den Betrieb mit HF-Druckfl üssigkeiten

Diese Druckschrift enthält zusätzliche Informationen zum Ein-satz von Rexroth-Verstellpumpen mit HF-Druckfl üssigkeiten.

• RD 90300-03-B: Hinweise zum Einsatz von hydrauli-schen Antrieben bei tiefen Temperaturen

Diese Druckschrift enthält zusätzliche Informationen zum Einsatz von Rexroth-Verstellpumpen bei tiefen Temperaturen.

1.3 Important DocumentsBefore you start any of the procedures described in this manu-al, make sure you have the following documents ready to hand:

• Confi rmation of Order

The confi rmation of order contains the values set during the commissioning by Rexroth. The variable pump may only be operated with the values and conditions specifi ed in the confi rmation of order.

• Installation Drawing

The installation drawing of the variable pump contains the sizes, all connections and the wiring diagram.

• Technical Data Sheet

The technical data sheets RE 92500 contain the maximum allowed technical data for the variable pumps and further information.

• Hydraulic Diagram / Wiring Diagram

The hydraulic diagram and the wiring diagram of the unit or system contain the information related to the hydraulic or electric connections. You need this data to work with the axial piston as part of the unit or system. You can get this information from the unit or system manufacturer.

• RE 90300-B: General Manual for Variable Pumps

The general manual supports you during the installation, initiation, and operation of Rexroth variable pumps.

• Product Specifi c Manual

The product-specifi c manual contains specifi c information designed for the variable pump. Get in touch with Rexroth to fi nd out if there is any product-specifi c information on your variable pump.

The following Rexroth publications provide additional informati-on to the installation and operation of variable pumps:

• RE 90220: Mineral-oil Based Pressure Fluids

This publication describes the requirements on a hydraulic fl uid based on mineral oil for operation in an variable pump and supports you in the selection of a hydraulic fl uid for your system.

• RE 90221: Environmentally Acceptable Hydraulic Fluids HEES, HEPG, HETG for Variable Pumps

This publication describes the demands on environmentally compatible, readily biodegradeable hydraulic fl uids HETG, HEPG, HEES that can be used in Rexroth variable pumps and supports you by the selection of a hydraulic fl uid for your system.

• RE 90223: Variable Pumps for Use with HF Fluids

This publication provides additional information for the use of Rexroth variable pumps with HF hydraulic fl uids.

• RE 90300-03-B: Instructions on the Use of Hydrostatic Drives at Low Temperatures

This publication provides additional information for the use of Rexroth variable pumps at low temperatures.


1.4 Gefahrenkennzeichnungen und PiktogrammeDiese Anleitung unterscheidet zwischen Kategorien von Gefah-ren gemäß ISO Guide 37:

GEFAHR!

Weist auf hohes Risiko und die Gefahr von Tod oder schwe-ren Verletzungen hin.

WARNUNG!

Weist auf mittleres Risiko und die Gefahr von Verletzungen und schweren Sachschäden hin.

VORSICHT!

Weist auf geringes Risiko und Sachschäden hin.

Hinweis

Kennzeichnet Informationen, die zum besseren Verständnis der Maschinenabläufe beitragen oder weist auf einen beson-deren bzw. wichtigen Sachverhalt hin.

Tipp

Kennzeichnet Informationen, die zum effi zienteren Arbeiten beitragen.

1.4 Danger Labels and Pictograms

This manual differentiates between the following categories of hazards, according to ISO Guide 37:

DANGER!

Indicates high risk, mortal danger and serious injuries.

WARNING!

Indicates middle risk, injuries or serious material damage.

CAUTION!

Indicates low risk or material damage.

Note

Indicates information that contributes to a better understan-ding of the machine processes or indicates important informa-tion.

Tip

Indicates information that contributes to more effi cient work.


2 SicherheitLesen Sie dieses Kapitel sorgfältig durch, bevor Sie mit Arbei-ten an der Verstellpumpe beginnen.

Die Rexroth-Verstellpumpen sind im Sinne der Maschinenricht-linie 98/37/EG Komponenten, die zum Einbau in eine Anlage bestimmt sind. Die Sicherheitsrichtlinien in dieser Anleitung be-ziehen sich nur auf die Verstellpumpe. Beachten Sie zusätzlich die Sicherheitsrichtlinien des Anlagenherstellers.

Informieren Sie sich an Hand der allgemeinen Betriebsan-leitung für Verstellpumpen über die bestimmungsgemäße Verwendung und die Sorgfaltspfl icht des Betreibers und Bedieners.

2.1 Grundlegende SicherheitshinweiseBefolgen Sie die folgenden Sicherheitshinweise und die des Anlagenherstellers genau, um Verletzungen und Gesundheits-schäden sowie Sach- und Umweltschäden auszuschließen.

GEFAHR!

Lebensgefahr

Das Arbeiten an nicht stillgelegten Maschinen bzw. Anlagen stellt eine Gefahr für Leib und Leben dar.

Die in diesem Dokument beschriebenen Arbeiten dürfen nur an stillgelegten Maschinen bzw. Anlagen vorgenommen werden. Bevor Sie mit den Arbeiten beginnen:

• Stellen Sie sicher, dass der Antriebsmotor nicht eingeschal-tet werden kann.

• Stellen Sie sicher, dass sämtliche kraftübertragenden Kom-ponenten und Anschlüsse (elektrisch, pneumatisch, hydrau-lisch) gemäß den Herstellerangaben ausgeschaltet sind und nicht eingeschaltet werden können. Falls möglich, entfernen Sie die Hauptsicherung der Maschine bzw. Anlage.

• Stellen Sie sicher, dass die Maschine bzw. Anlage komplett hydraulisch entlastet ist (drucklos). Folgen Sie hierzu den Angaben des Maschinen- bzw. Anlagenherstellers.

WARNUNG!

Verletzungsgefahr

Um Verletzungen zu vermeiden, beachten Sie bitte folgende Empfehlungen betreffend Sicherheitskleidung:

• Tragen Sie bei Arbeiten an Maschine bzw. Anlage Sicher-heitsschuhe mit Stahlkappen.

• Tragen Sie bei Arbeiten mit gefährlichen Stoffen (beispiels-weise Druckfl üssigkeiten) Schutzhandschuhe und Schutz-brille.

2 SafetyRead through this chapter carefully before you start any work on the variable pump.

The Rexroth variable pumps are in the sense of the machine guideline 98/37/EG components of a system. The safety gui-delines in this manual only cover the variable pump. You must additionally follow the system manufacturer’s safety guidelines.

Read the general manual for variable pump units to get more information on the designated use and the operator‘s obligati-on to exercise diligence.

2.1 Basic Safety Information

Pay attention to the following safety information and that of the system manufacturer to eliminate injuries and health damages as well as damages to material or the environment.

DANGER!

Danger to life

Working on systems that have not been shut down completely is life-threatening.

The work described in this document must only be carried out on a shut down system. Before you start any of the tasks:

• Make sure that the motor cannot be switched on.

• Make sure that all components and connections that carry energy (electrical, pneumatic, hydraulic) have been shut down according to the manufacturer’s instructions and cannot be switched on. If possible, remove the main fuse.

• Make sure that the system is completely unpressurized. Follow the instructions of the system manufacturer.

WARNING!

Danger of injury

To avoid injuries, pay attention to the following recommendati-ons regarding safety clothing:

• When working on the system, wear steel-toed safety shoes.

• When working with dangerous substances (for example, certain hydraulic fl uids), wear protective gloves and protec-tive glasses.


GEFAHR!

Vergiftungs- und Verletzungsgefahr

Der Kontakt mit Druckfl üssigkeiten ruft Gesundheitsschäden hervor (z.B. Augenverletzungen, Haut- und Gewebeschädi-gungen, Vergiftungen beim Einatmen).

• Überprüfen Sie vor jeder Inbetriebnahme die Leitungen auf Verschleiß bzw. Beschädigungen.

• Tragen Sie dabei Schutzhandschuhe und Schutzbrille.

• Wenn dennoch Druckfl üssigkeit in die Augen gelangt oder in die Haut eindringt, konsultieren Sie unmittelbar einen Arzt.

• Beachten Sie beim Umgang mit Druckfl üssigkeiten unbe-dingt die Sicherheitsangaben des Druckfl üssigkeitsherstel-lers.

WARNUNG!

Verbrennungsgefahr

Die Verstellpumpe erwärmt sich während des Betriebs. Auch die Magnete an der Verstellpumpe werden im laufenden Betrieb heiß. Finger und Hände können bei Berührung der Verstellpumpe oder der Magnete schwere Brandverletzungen erleiden.

• Lassen Sie die Verstellpumpe vor jedem Kontakt abkühlen.

• Schützen Sie sich mit hitzebeständigen Handschuhen und Schutzkleidung.

GEFAHR!

Vergiftungs- und Verletzungsgefahr

Beim Suchen nach Leckstellen kann entweichende Druckfl üs-sigkeit in die Haut eindringen und schwerste Vergiftungen und Verletzungen hervorrufen.

• Suchen Sie nur bei abgestellter und druckloser Maschine nach Leckstellen.

WARNUNG!

Verletzungs- und Beschädigungsgefahr

Durch falsch angeschlossene Komponenten können erhebli-che Fehlfunktionen entstehen.

• Achten Sie auf korrekte Verrohrung gemäß Schaltplan.

• Führen Sie komponentenorientierte Funktionstests durch.

DANGER!

Danger of poisoning or injury

Contact with hydraulic fl uids can cause health damage (e. g. eye injuries, skin and tissue damage, poisoning due to inhalati-on).

• Always check the hydraulic lines for wear and damage prior to putting the unit into operation.

• When checking the lines, wear protective gloves and safety glasses.

• Should pressure fl uid come into contact with your eyes or skin: Get medical help immediately!

• When handling hydraulic fl uids, pay attention to the hydrau-lic fl uid manufacturer’s safety instructions.

WARNING!

Danger of burns

The variable pump heats up during operation. The unit’s solenoids get hot during operation. Fingers and hands can be badly burned when touching the variable pump or solenoids.

• Let the variable pump cool down prior to any contact.

• Protect yourself from burns by wearing safety gloves and protective clothing.

DANGER!

Danger of poisoning and injuries

When looking for leaks, escaping hydraulic fl uid can break into the skin and cause serious poisoning and injuries.

• Look only for leaks, if the variable pump unit is shut down and unpressurized.

WARNING!

Danger of injuries or damage

Incorrectly connected components can considerably impair the functionality of a hydraulic system.

• Make sure that the hydraulic lines are connected properly according to the wiring diagram.

• Check the correct functioning of all components.


GEFAHR!

Feuergefahr

Hydraulische Druckfl üssigkeit ist brennbar.

• Halten Sie offenes Feuer und Zündquellen von der Verstell-pumpe fern.

WARNUNG!

Gehörschäden

Die Geräuschemission von Verstellpumpen ist u.a. von Dreh-zahl, Betriebsdruck und Einbauverhältnissen abhängig. Es ist damit zu rechnen, dass der Schalldruckpegel bei normalen Einsatzbedingungen über 70 dBA steigt. Dies kann zu Gehör-schäden führen.

• Schützen Sie sich stets mit Gehörschutz bei Arbeiten in der Nähe der Verstellpumpe während des laufenden Betriebs.

WARNUNG!

Umweltschäden

Druckfl üssigkeiten sind wassergefährdende Flüssigkeiten. Das Austreten von Druckfl üssigkeiten kann zu Grundwasser-vergiftung und Bodenverseuchung führen.

• Bringen Sie unter der Verstellpumpe eine Auffangwanne an.

• Beseitigen Sie Leckstellen unverzüglich.

• Es sind stets die nationalen Gesetze und Vorschriften zu beachten. In Deutschland sind hydraulische Maschinen bzw. Anlagen „Anlagen zum Umgang mit wassergefährdenden Stoffen im Sinne des Wasserhaushaltsgesetzes (WHG)“. Beachten Sie in diesem Zusammenhang besonders §1 und §19 WHG (§19g, 19i, 19l).

• Weitere Informationen fi nden Sie in den Rexroth-Druckschriften „Druckfl üssigkeiten auf Mineralölbasis“, RD 90 220, „Umweltschonende, biologisch schnell abbau-bare Druckfl üssigkeiten HEPG, HEES für Axialkolbenma-schinen“, RD 90 221-1 und „Axialkolbenmaschinen für den Betrieb mit HF-Druckfl üssigkeiten, RD 90 223.

DANGER!

Danger of fi re

Hydraulic fl uid is infl ammable.

• Keep open fi res and ignition sources away from the variable pump.

WARNING!

Danger of hearing damage

The noise emission produced by variable pump units depends on speed, operating pressure, and installation. During normal application conditions, over 70 dBA can be anticipated. This can lead to hearing damage.

• Always wear hearing protection when working in the vicinity of the variable pump during operation.

WARNING!

Risk of damage to the environment

Hydraulic fl uid is hazardous to waters.Hydraulic fl uid leakage leads to contamination of the ground and ground water.

• A basin for catching any hydraulic fl uid must be placed under the variable pump.

• Leaks must be cleaned up immediately.

• Pay always attention to any national regulations and norms.In Europe, hydraulic systems are considered “Systems using water-threatening substances” in the sense of the Water Management Law (WHG).Therefore, pay special attention to §1 and §19 WHG (§19g, 19i, 19l).

• Further information is available in the Rexroth publications „Mineral-oil based hydraulic fl uids“, RE 90 220. „Environ-mentally acceptable, rapid biologically degradable hydraulic fl uids HEPG, HEES for axial piston units“, RE 90 221-1 and „Axial piston units for operation with HF hydraulic fl uids, RE 90 223.


2.2 Anforderungen an das PersonalDiese Reparaturanleitung richtet sich an Fachkräfte mit Hydraulik-Fachwissen, die an einer Service-Schulung bei Rexroth teilgenommen haben.

Als Fachkraft gilt, wer aufgrund seiner fachlichen Ausbildung und Erfahrung ausreichende Kenntnisse hat, sowie mit den einschlägigen Bestimmungen so weit vertraut ist, dass er

• die ihm übertragenenen Arbeiten beurteilen kann,

• mögliche Gefahren erkennen kann,

• die notwendigen Maßnahmen zur Beseitigung von Gefahren ergreifen kann,

• Kenntnisse über die möglichen Gesundheitsgefahren von Druckfl üssigkeiten hat

• und die erforderlichen Reparatur- und Montagekenntnisse hat.

Hydraulik-Fachwissen bedeutet, das Personal muss

• in der Lage sein, die Hydraulikpläne zu lesen und vollständig zu verstehen,

• insbesondere die Zusammenhänge bezüglich der eingebau-ten Sicherheitseinrichtungen vollständig verstehen

• und Kenntnisse über Funktion und Aufbau von hydraulischen Bauteilen haben.

2.2 Requirements on the PersonnelThis repair manual is directed at qualifi ed personnel with specialized hydraulics know-how who have taken part at a service training at Rexroth.

Qualifi ed personnel is defi ned as persons who have suffi cient knowledge on the basis of specialized training and experience, and are familiar with the relevant regulations, so that they are able to

• judge the delegated tasks,

• recognize possible dangers,

• take the necessary measures for the elimination of dangers,

• know the possible health risks from hydraulic fl uids,

• and have the required repair and installation know-how.

Specialized hydraulics know-how means that the personnel must:

• be able to read and completely understand hydraulic plans

• especially understand completely the coherences regarding the installed safety equipment

• be familiar with the function and structure of hydraulic com-ponents.


3 ProduktbeschreibungDieses Kapitel gibt Ihnen einen allgemeinen Überblick über die Funktionalität der Rexroth A11VO/A11VLO Verstellpumpen.

Machen Sie sich mit den Inhalten dieses Kapitels vertraut, bevor Sie mit Arbeiten an einer Verstellpumpe beginnen.

3.1 TypschildDie Verstellpumpe ist am Typschild zu identifi zieren (Beispiel):

1

3

45

6

2 7

9

10

8

Folgende Informationen fi nden Sie auf dem Typschild:

1 Hersteller

2 Typschlüssel

3 Materialnummer der Axialkolbenmaschine

4 Seriennummer

5 Fertigungsdatum

6 Drehzahl

7 interne Werksbezeichnung

8 Drehrichtung (bei Blick auf die Welle; hier: im Uhrzeiger-sinn)

9 Vorgesehener Platz für Prüfstempel

10 Leistung

Stellen Sie sicher, dass Typ und Nenngröße der zu reparieren-den Verstellpumpe mit dieser Anleitung übereinstimmen.

3.2 Funktionsbeschreibung Damit Sie in der Lage sind, Probleme an der Verstellpumpe zu identifi zieren und gezielt Reparaturen durchzuführen, sind Kenntnisse der Funktionsweise und des Aufbaus erforderlich. Dieser Abschnitt gibt Ihnen eine grobe Übersicht.

Die A11VO/A11VLO Verstellpumpen sind Axialkolben-Verstell-pumpe in Schrägscheibenbauart für hydrostatische Antriebe im offenen Kreislauf. Der Volumenstrom ist proportional zu der Antriebsdrehzahl und dem Verdrängungsvolumen. Durch die Verstellung der Schrägscheibe ist eine stufenlose Volumen-stromänderung möglich.

A11VLO Pumpen haben einen eingebauten Impeller (Ladepum-pe). Das ist eine Kreiselpumpe, die es erlaubt, die Pumpen mit höheren Drehzahlen zu betreiben.

3 Product DescriptionThis chapter provides a general overview of the functionality of the A11VO/A11VLO variable displacement pumps.

You should be familiar with the contents of this chapter before starting any work on the variable displacement pump.

3.1 Name PlateThe variable displacement pump can be identifi ed on its type plate (example):

The following information can be found on the type plate:

1 Manufacturer

2 Ordering code

3 Material number of the axial piston unit

4 Serial number

5 Date of manufacturing

6 Speed

7 Internal manufacturing code

8 Direction of rotation (when facing the shaft; here: clockwi-se)

9 Designated space for certifi cation stamp

10 Power

Ensure that the variable displacement pump to be repaired is of the type and size covered by this manual.

3.2 Functional DescriptionTo make sure that you are able to identify problems with a variable displacement pump and to carry out specifi c repairs, familiarity with how the unit functions and its assembly are required. This section provides you with a rough overview.

The variable displacement axial piston pumps type A11VO/A11VLO in swashplate design are designed for open circuit hydrostatic drives. The fl ow is proportional to the input drive speed and displacement. By adjusting the swashplate, it is possible to infi nitely vary the fl ow.

A11VLO pumps have a built-in impeller. This is a turbo pump that makes it possible to increase the rotational speed for driving the pumps.

TYP:MNR:

SN:FD: Rotation:

D-89275 Elchingen

Made in Germany

A11VLO190LRDS/10R-NZD12N00R90XXXXXXX

12345678

Rexroth

07W09

7202

n = XXXX min-1 p = XXX kW


Sectional Drawings

The following drawings show the design of the A11VO/A11VLO variable displacement pump.

Qmin Stop / Qmax Stop: Stop for minimum/maximum swivel angle.

Schnittzeichnungen

Die folgenden Schnittzeichnungen zeigen den Aufbau der A11VO/A11VLO Verstellpumpe.

A11VLO 190, 260 LRDS

Antriebswelle /Drive Shaft

Triebwerk /Rotary Unit

Regler /Control Unit

Qmin Stop

Qmax Stop

Verschlussring mit Wellen-dichtring /Cover Ring with Shaft Seal

Ladepumpe / Impeller

Qmin Stop / Qmax Stop: Anschlag für minimalen/maximalen Schwenkwinkel.

Reglerbeispiele / Control Unit Examples

LRDS LRDH

DRS


EP

LR: Leistungsregler Power Control

D, DR: Druckregler Pressure Control

S: Load-Sensing Load-Sensing Control

EP: Elektrische Verstellung Electrical Control

HD: Hydraulische Verstellung Hydraulic Control

3.3 Technische DatenDie technischen Daten der Verstellpumpe fi nden Sie in der Auftragbestätigung. Ergänzend dazu ist das jeweilige techni-sche Datenblatt. Für die A11VO/A11VLO Verstellpumpe gilt das technische Datenblatt RD 92500.

3.3 Technical DataYou can fi nd the technical data for the variable displacement pump in the Confi rmation of Order. This is supplemented by the unit‘s data sheet. For the A11VO/A11VLO variable dis-placement pump, the valid data sheet is RE 92500.


4 Austausch externer BaugruppenDieses Kapitel beschreibt den Austausch von Baugruppen und Dichtungen der Verstellpumpen A11VO/A11VLO.

Der Austausch von Dichtungen folgender Baugruppen wird beschrieben:

• Triebwelle

• Regler

• Dichtmuttern

WARNUNG!

Gefahr von Verschleiß und Funktionsstörungen

Die Sauberkeit der Druckfl üssigkeit und die Lebensdauer der Hydraulikanlage stehen in unmittelbarem Zusammenhang. Verschmutzung der Druckfl üssigkeit führt zu Verschleiß und Funktionsstörungen. Insbesondere harte Fremdkörper in den Hydraulikleitungen, wie z.B. Schweißperlen und Metallspäne, beschädigen die Axialkolbenmaschine.

Beachten Sie daher unbedingt folgende Hinweise:

• Achten Sie auf äußerste Sauberkeit. Die Axialkolbenmaschi-ne muss schmutzfrei eingebaut werden. Verunreinigungen in der Druckfl üssigkeit können die Funktion und Lebensdau-er der Axialkolbenmaschine erheblich beeinträchtigen.

• Achten Sie besonders bei der Installation darauf, dass Anschlüsse, Hydraulikleitungen und Anbauteile ( z.B. Mess-geräte) sauber sind. Reinigen Sie diese gründlich, bevor Sie Anschlüsse öffnen. Stellen Sie sicher, dass auch beim nachfolgenden Verschließen der Anschlüsse keine Verunrei-nigungen eindringen.

• Verwenden Sie für die Beseitigung von Schmiermitteln und anderen starken Verschmutzungen geeignete fl üssige Reini-gungsmittel. Es darf kein Reinigungsmittel in das Hydraulik-system eindringen.

• Verwenden Sie zur Reinigung keine Putzwolle oder fasern-de Putzlappen.

• Verwenden Sie als Dichtungsmittel keinesfalls Hanf oder Kitt.

4 Exchanging External Assembly GroupsThis chapter describes the replacement of the externally ac-cessible assembly groups and sealings of the variable pumps A11VO/A11VLO.

The exchange of sealings of the following assembly groups is described:

• Drive shaft

• Control unit

• Seal Locks

WARNING!

Danger of wear and malfunction

The durability of the hydraulic unit depends to a great extent on how clean the unit is kept. Dirt in the hydraulic fl uid can lead to malfunctions. Especially hard foreign matter in the hy-draulic lines, for example, welding beads and metal cuttings, will defi nitely damage the axial piston unit.

Therefore you should observe the following instructions:

• Make sure everything is kept extremely clean. The axial pis-ton unit must be installed in a dirt-free environment. Conta-mination of the hydraulic fl uid can lead to considerable wear and malfunctions of the axial piston unit.

• Especially during the installation, you should make sure that ports, hydraulic conduits, and mounting components (for example, gauges) are clean. Clean these thoroughly before you open connections. After that, when sealing the ports, make sure that contaminating elements cannot enter the system.

• When removing grease and other dirt you should use ap-propriate liquid cleaning agents. Cleaning agents must not enter the hydraulic system.

• Do not use cotton waste or rags which lose threads.

• Never use hemp or putty as a sealant.


4.1 Triebwelle abdichtenDieser Abschnitt erklärt, wie Sie die Triebwelle abdichten.

Benötigtes Sonderwerkzeug:

• Montagebüchse

Die Materialnummern sind je nach Pumpenmodell verschie-den:

A11VO/A11VLO

– NG 190: Mat. Nr. R90450647

– NG 260: Mat. Nr. R90450941

a: Sicherungsring Circlip

b: Verschlussring Cover Ring

c: Wellendichtring Shaft Seal

d: O-Ring O-ring

e: Triebwelle Drive Shaft

e

a

bd

c

Um die Triebwelle abzudichten:

1 Kleben Sie die Triebwelle (e) ab, um Beschädigungen bei der Montage des neuen Wellendichtrings zu vermeiden.

e

4.1 Sealing the Drive ShaftThis section explains how you seal the drive shaft.

Required Special Tools:

• Mounting sleeve

The material number depends on the pump model:

A11VO/A11VLO

– Size 190: Mat. no. R90450647

– Size 260: Mat. no. R90450941

To seal the drive shaft:

1 Mask the drive shaft (e) for damage protection while repla-cing the shaft seal.


2 Remove the circlip (a).

3 Press off the cover ring (b).This action removes also the shaft seal that is pressed into the cover ring.

4 Remove the shaft seal (c) from the cover ring (b) and the o-ring (d) from the housing.

Check the cover ring (b), the drive shaft (e), and the housing (f) for wear and dirt.

2 Entfernen Sie den Sicherungsring (a).

a

3 Drücken Sie den Verschlussring (b) ab.Damit entfernen Sie auch den Wellendichtring, der in den Verschlussring eingepresst ist

b

4 Entfernen Sie den Wellendichtring (c) aus dem Verschluss-ring (b) sowie den O-Ring (d) aus dem Gehäuse.

Kontrollieren Sie den Verschlussring (b), die Triebwelle (e) und das Gehäuse (f) auf Verschleiß und Verunreinigungen.

df

e

bc


5 Using the suitable mounting bush (g) (special tool), press in the shaft seal (c) until it is correctly orientated in the cover ring.

If the shaft is deeply grooved, insert a shim behind the shaft seal.

6 Grease the new shaft seal between the seal and dust lips to avoid a dry run.

7 Grease the the new o-ring (d) slightly and insert it into the housing (f). Ensure, that it is correctly placed.

8 Insert the cover ring with the shaft seal into the housing.

9 Place the safety ring (a) into the housing (f) so that it locks into place in the respective slot of the cover ring.

Check to ensure that the circlip is correctly located within the groove.

10 Remove the mask from the drive shaft.

5 Pressen Sie den Wellendichtring (c) mit Hilfe der passenden Montagebüchse (g) (Sonderwerkzeug) lagerichtig in den Verschlussring ein.

gg

c

Bei tiefer Laufrille legen Sie eine Scheibe auf den Wellen-dichtring.

6 Fetten Sie den neuen Wellendichtring zwischen Dicht- und Staublippe leicht ein, um Trockenlauf zu vermeiden.

7 Fetten Sie den neuen O-Ring (d) leicht ein und legen Sie ihn in das Gehäuse (f) ein. Prüfen Sie, ob der O-Ring bündig anliegt.

f

d

8 Setzen Sie den Verschlussring mit dem Wellendichtring in das Gehäuse ein.

9 Führen Sie den Sicherungsring (a) so in das Gehäuse (f) ein, dass er in die dafür vorgesehene Nut des Verschlussrings einrastet.Kontrollieren Sie den Sitz des Sicherungsrings in der Nut.

af

10 Entfernen Sie die Abklebung der Triebwelle.


4.2 Reglergehäuse abdichtenDas Reglergehäuse wird mit vier O-Ringen gegen die An-schlussplatte abgedichtet.

a: Anschlussplatte Port Plate

b: Regler Control Unit

c: O-Ringe O-rings

d: Messkolben mit Winkelhebel Measuring Piston with angled Lever

c

b

a

d

4.2 Sealing the Control Unit HousingFour o-rings are used to seal the regulator housing from the port plate.


Control Unit Example, LRDS

Note

Do not change the position of adjustment screws. If necessa-ry, remove the complete set of threaded bush with adjustment screws.

CAUTION!

Before removing a control unit with measuring spring (for example LRDH, EP):First remove the control bush with the measuring spring, then remove the regulator housing!

Regler, z. B. LRDS

LR

DS

LR: Leistungsregler Power control

D: Druckregler Constant pressure control

S: Load-sensing Regler Load-sensing valve

Hinweis

Einstellschrauben nicht verändern. Falls erforderlich, Gewin-dehülse komplett mit Einstellschrauben ausbauen.

VORSICHT!

Vor dem Abschrauben eines Reglers mit Messfeder (z. B. LRDH, EP):Zuerst Steuerbuchse mit Messfeder ausbauen, dann Regler-gehäuse abbauen!.


Example of a Control Unit with Measuring Spring

To seal the control unit:

1 Remove the fi ve fi xing screws.

2 Press off the control unit.

CAUTION!

Make sure that the sealing surface is not damaged!

3 Insert four new o-rings into the grooves of the port plate.

Beispiel für einen Regler mit Messfeder

EP

Ausbauen /Remove

Um den Regler abzudichten:

1 Entfernen Sie die fünf Befestigungsschrauben.

2 Drücken Sie den Regler ab.

VORSICHT!

Dichtfl äche nicht beschädigen!

3 Legen Sie vier neue O-Ringe in die Anschlussplatte ein.


4 Achten Sie vor dem Aufsetzen des Reglers auf die korrekte Positionierung von Messkolben und Winkelhebel (d).

d

5 Ziehen Sie die fünf Befestigungsschrauben an.

4.3 Dichtungen austauschenDieser Abschnitt erklärt, wie Sie die Dichtmuttern ersetzen.

Benötigtes Sonderwerkzeug: Keines

Um eine Dichtmutter auszutauschen:

1 Messen und notieren Sie das Maß X für die spätere Montage der Dichtmutter (a).

Entfernen Sie die Dichtmutter.

X

a

2 Schrauben Sie die neue Dichtmutter (a) ein. Blockieren Sie die Stellschraube (b) während Sie die Dichtmutter festzie-hen.Kontrollieren Sie das Maß X nach der Montage.

ab

4 Before mounting the regulator ensure that the measuring piston and angled lever (d) are correctly positioned.

5 Insert and tighten the fi ve fi xing screws

4.3 Replacing SealsThis section explains how you replace the seal nuts.

Required special tools: None

To replace a seal nut:

1 Measure and write down the dimension X of the seal nut (a). You need this for the subsequent assembly.

Remove the seal nut.

2 Screw in the new seal lock (a) manually. Block the adjusting screw (b) while you tighten the seal nut.

Check the dimension X after assembly.


Anziehdrehmomente für Seal-Lock Dichtmuttern(nach N 02.100)

Gewinde / Thread

Anziehdrehmoment MA in NmTightening torque MA in Nm

M6 10

M6 x 0,5 11

M8 22

M8 x 1 24

M10 40

M10 x 1 44

M12 69

M12 x 1,5 72

M14 110

M14 x 1,5 120

M16 170

M16 x 1,5 180

Tightening Torques for Seal-Lock Sealing Nuts(according to N 02.100)


5 FunktionsprüfungenDieses Kapitel gibt Ihnen Beispiele, wie Sie die Funktion einer Rexroth A11VO/A11VLO Verstellpumpe mit LRDS-Regler überprüfen können.

5.1 Vorbereitungen1 Fordern Sie das Leistungsdiagramm bei Bosch Rexroth an.

2 Überprüfen Sie die Drehrichtung.

3 Bauen Sie die Pumpe ein, befestigen Sie sie, und befüllen Sie das Gehäuse.

Anschlüsse / Ports

A11VO/A11VLO 190 ... 260 LRDS

LR

S

D

X

M G

M: Messstelle Arbeitsanschluss Test port for pressure

M1: Messstelle Stellkammer Test port for stroking cylinder

LR: Leistungsregler Power Control

D: Druckabschneidung Pressure Cut-off

S: Load-Sensing-Regler Load-Sensing Control

X: Anschluss für LS-Regler Port for LS Control

G: Anschluss für Fremd-stelldruck

Port for externally applied control pressure

X

M1

5 Functional ChecksThis chapter provides examples on how to check the proper function of a Rexroth A11VO/A11VLO variable pump with LRDS regulator.

5.1 Preparations1 Order the power curve diagram at Bosch Rexroth.

2 Check the direction of rotation.

3 Install and fi x the pump. Fill the housing.


5.2 Checking the Load-Sensing Control (S)

Setting process

1 Heat up the system to test temperature

2 Set drive speed

3 Screw out Qmin stop

4 Use the following test setup

Test Setup

Connections

5.2 Prüfung des Load-Sensing Reglers (S)

Einstellvorgang

1 Auf Prüftemperatur fahren

2 Antriebsdrehzahl einstellen

3 Qmin Anschlag ausschrauben

4 Verwenden Sie folgenden Testaufbau

Testaufbau

Belastungsventil / Charge Valve

Messmotor-Volumenstrommessgerät / Measuring Motor

Messblende - Absperrhahn / Measuring Throttle - Locking Tap

Dreiwegehahn / 3-Way Tap

pHD2

pHD1

pdiff

Anschlüsse

M1

M A, G X

S

Load-Sensing-Regler / Load-Sensing Control

Druckregler / Constant Pres-sure Control

Leistungsregler / HP-Control

Dreiwegehahn / 3-Way Tap

Messblende - Absperrhahn / Measuring Throttle - Locking Tap


5 Messblende/Absperrhahn vorsichtig schließen bis Qmax/2 (halber Volumenstrom). Hochdruck 100 bar (pHD2) nach der Messblende (Belas-tungsventil) einstellen.

6 pdiff am LS-Regler einstellen und kontern.

Zum Beispiel: pdiff = 18 bar:

pHD2 = 100 bar

pHD1 = 118 bar

7 Dreiwegehahn in der X-Leitung vorsichtig schließen.

8 Qmin Schraube anlegen, 1/2 Umdrehung wieder herausdre-hen und kontern.

5.3 Prüfung des Leistungsreglers (LR)

Einstellvorgang

1 Druckregler blockieren (eindrehen).

2 Leistungsregler nach Leistungsdiagramm (LD) einstellen.

3 Messblende, Absperrhahn öffnen.

4 Förderstrom Qmax einstellen (Qmax-Schraube).

Beispiel 1

Einstellung des Regelbeginns über einen Punkt auf der Leis-tungskennlinie nach Druck und Volumen.

5 Carefully close the measuring throttle's locking tap up to Qmax/2 (half fl ow). Set high pressure 100 bar (pHD2) behind the measuring throttle (charge valve).

6 Set pdiff at the HP-control and jam the screw.

For example: pdiff = 18 bar:

pHD2 = 100 bar

pHD1 = 118 bar

7 Close the measuring throttle's locking tap entirely.

8 Place Qmin screw, screw-out again 1/2 rotation and jam the screw.

5.3 Checking the Power Control (LR)

Setting process

1 Block constant pressure control (screw-in).

2 Set the power control as to HP diagram (power diagram).

3 At the measuring throttle, open the locking tap.

4 Set fl ow to Qmax (Qmax screw).

Example 1

Setting the start of regulation at a point of the horse power diagram (pressure/fl ow).


Beispiel 2

Einstellung des Regelbeginns. Druck (Stelldruck) an M1.

Hinweis

Diese Einstellung ist „ungenau“ (Toleranz).

Beispiel:

Regelbeginn = 120 bar.

Betriebsdruck langsam erhöhen bis Manometer an M = 120 bar anzeigt. Ddabei darf der Stelldruck an M1 ca. 1/3 vom Betriebsdruck, also etwa 40 bar betragen.

Das ist der Regelbeginn.

Zum Beispiel:

Druck an M = 120 bar

Druck an M1 = 20 bar

Regelbeginn zu spät, also Leistungsüberschreitung

Einstellschraube herausdrehen bis ca. 40 bar erreicht werden.

M =120 bar

M1 =40 bar

Example 2

Setting the start of regulation, pressure (stroking pressure) at M1.

Note

This setting is „unprecise“ (Tolerance).

Example:

Begin of regulation = 120 bar.

Slowly increase operation pressure up to pressure gauge at M = 120 bar. The positioning pressure at M1 may be up to approx. 1/3 of the operation pressure, i.e. approx. 40 bar.

This is the start of the regulation.

For example:

Pressure at M = 120 bar

Pressure at M1 = 20 bar

Start of regulation too late, i.e. Power excess.

Unscrew setting screw until approx. 40 bar are reached.


5.4 Prüfung des Druckreglers (D) Einstellung des Druckreglers mittels Belastungsventil nach Leistungsdiagramm.

Beispiel: Druckreglereinstellung = 310 bar

1 Betriebsdruck mit Belastungsventil auf ca. 350 bar erhöhen.

2 Blockierten Druckregler vorsichtig herausdrehen bis 310 bar erreicht werden.

3 Einstellschraube kontern.

5.4 Checking the Pressure Control (D) Setting with help of the charge valve the constant pressure control as to HP diagram.

Example: Setting of constant pressure control = 310 bar

1 Increase operation pressure with help of charge valve to approx. 350 bar.

2 Unscrew blocked constant pressure control carefully until 310 bar are reached.

3 Jam setting screw.


© This document, as well as the data, specifi cations and other information set forth in it, are the exclusive property of Bosch Rexroth AG. It may not be reproduced or given to third parties without its consent.

The data specifi ed above only serve to describe the product. No statements concerning a certain condition or suitability for a certain application can be derived from our informa-tion. The information given does not release the user from the obligation of own judgment and verifi cation. It must be remembered that our products are subject to a natural process of wear and aging.

Subject to change.

Bosch Rexroth AG HydraulicsProduktsegment Axi al kol ben ma schi nenWerk Elchingen Glockeraustraße 2 89275 Elchingen, GermanyTelefon +49 (0) 73 08 82-0Telefax +49 (0) 73 08 [email protected] www.boschrexroth.com/brm

© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.

Die angegebenen Daten dienen allein der Produktbeschreibung. Eine Aussage über eine bestimmte Beschaffenheit oder eine Eignung für einen bestimmten Einsatzzweck kann aus unseren Angaben nicht abgeleitet werden. Die Angaben entbinden den Verwender nicht von eigenen Beurteilungen und Prüfungen. Es ist zu beachten, dass unsere Produk-te einem natürlichen Verschleiß- und Alterungsprozess unterliegen.

Änderungen vorbehalten.

HY13-1512-004-M1/US

TorqmotorTM

Service Procedure

Effective: March 2005

TC, TB, TE, TJ, TF,TG, TH and TL SeriesLow Speed, High TorqueHydraulic TorqmotorsTM

HY13-1512-004-M1/USA Torqmotor™ Service ProcedureTC,TB, TE, TJ, TF, TG, TH and TL Series

Parker Hannifin CorporationHydraulic Pump/Motor DivisionGreeneville, TN 37745 US

2

FAILURE OR IMPROPER SELECTION OR IMPROPER USE OF THE PRODUCTS AND/OR SYSTEMS DESCRIBED HEREIN ORRELATED ITEMS CAN CAUSE DEATH, PERSONAL INJURY AND PROPERTY DAMAGE.This document and other information from Parker Hannifin Corporation, its subsidiaries and authorized distributors provide product and/orsystem options for further investigation by users having technical expertise. It is important that you analyze all aspects of your applicationand review the information concerning the product or system in the current product catalog. Due to the variety of operating conditions andapplications for these products or systems, the user, through its own analysis and testing, is solely responsible for making the final selectionof the products and systems and assuring that all performance, safety and warning requirements of the application are met.The products described herein, including without limitation, product features, specifications, designs, availability and pricing, are subject tochange by Parker Hannifin Corporation and its subsidiaries at any time without notice.

WARNING

The items described in this document are hereby offered for sale by Parker Hannifin Corporation, its subsidiaries or its authorized distributors.This offer and its acceptance are governed by the provisions stated in the "Offer of Sale".

©©©©© Copyright 2005, 2000, 1999, Parker Hannifin Corporation, All Rights Reserved

Offer of Sale



3

Definitions ............................................................................................................................................................... 3Design Features .................................................................................................................................................4 - 5Introduction ............................................................................................................................................................. 7Troubleshooting Guide ............................................................................................................................................. 8Troubleshooting Checklist ....................................................................................................................................... 9Tools and Material Required for Servicing .............................................................................................................. 10Bolt Torque ............................................................................................................................................................ 11Exploded Assembly View ................................................................................................................................. 12-13TC Service Parts List Chart ............................................................................................................................. 14-15TB Service Parts List Chart ............................................................................................................................. 16-17TE Service Parts List Chart ............................................................................................................................. 18-19TJ Service Parts List Chart ................................................................................................................................... 20TF Service Parts List Chart ............................................................................................................................. 21-22TG Service Parts List Chart ............................................................................................................................. 23-24TH Service Parts List Chart ............................................................................................................................. 25-26TL Service Parts List Chart ................................................................................................................................... 27Disassembly & Inspection ............................................................................................................................... 28-35Torqmotor™ Assembly ..................................................................................................................................... 36-45Rotor Set Component Assembly Procedure (One Piece Stator) ............................................................................ 46Rotor Set Component Assembly Procedure (Two Piece Stator) ........................................................................ 47-48Final Checks ......................................................................................................................................................... 49Hydraulic Fluids .................................................................................................................................................... 49Filtration, Oil Temperature ..................................................................................................................................... 49Tips for Maintaining the System............................................................................................................................ 50Offer of Sale ................................................................................................................................ Inside Back Cover

DefinitionsNOTE: A NOTE provides key information to make a procedure easier or quicker to complete.

CAUTION: A CAUTION refers to procedure that must be followed to avoid damaging the Torqmotor™ or other systemcomponents.

WARNING: A WARNING REFERS TO PROCEDURE THAT MUST BE FOLLOWED FOR THE SAFETY OF THEEQUIPMENT OPERATOR AND THE PERSON INSPECTING OR REPAIRING THE TORQMOTOR™.

DisclaimerThis Service Manual has been prepared by Parker Hannifin for reference and use by mechanics who have been trained torepair and service hydraulic motors and systems on commercial and non-commercial equipment applications. ParkerHannifin has exercised reasonable care and diligence to present accurate, clear and complete information and instructionsregarding the techniques and tools required for maintaining, repairing and servicing the complete line of Parker TC, TB, TE,TJ, TF, TG and TL TorqmotorTM Units. However, despite the care and effort taken in preparing this general Service Manual,Parker makes no warranties that (a) the Service Manual or any explanations, illustrations, information, techniques or toolsdescribed herein are either accurate, complete or correct as applied to a specific Torqmotor™ unit, or (b) any repairs orservice of a particular Torqmotor™ unit will result in a properly functioning Torqmotor™ unit.

If inspection or testing reveals evidence of abnormal wear or damage to the Torqmotor™ unit or if you encounter circum-stances not covered in the Manual, STOP – CONSULT THE EQUIPMENT MANUFACTURER’S SERVICE MANUAL ANDWARRANTY. DO NOT TRY TO REPAIR OR SERVICE A TORQMOTOR™ UNIT WHICH HAS BEEN DAMAGED OR IN-CLUDES ANY PART THAT SHOWS EXCESSIVE WEAR UNLESS THE DAMAGED AND WORN PARTS ARE REPLACEDWITH ORIGINAL PARKER REPLACEMENT AND SERVICE PARTS AND THE UNIT IS RESTORED TO PARKER SPECIFICA-TIONS FOR THE TORQMOTOR™ UNIT.

It is the responsibility of the mechanic performing the maintenance, repairs or service on a particular Torqmotor™ unit to (a)inspect the unit for abnormal wear and damage, (b) choose a repair procedure which will not endanger his/her safety, thesafety of others, the equipment, or the safe operation of the Torqmotor™, and (c) fully inspect and test the Torqmotor™ unitand the hydraulic system to insure that the repair or service of the Torqmotor™ unit has been properly performed and that theTorqmotor™ and hydraulic system will function properly.

Table of Contents



4

COUPLING SHAFT

HIGH PRESSURE SEAL

NEEDLE THRUST BEARING

HOUSING

DRIVE LINK—12-TOOTHSPLINES

DIRT & WATER SEAL

MATCHED ROTOR SET

MATCHED COMMUTATOR SET

NEEDLE RADIALBEARING

Torqmotor™ TE Series featuresinclude:• Roller vanes to reduce friction andinternal leakage and to maintain efficiency.

• Zero leak commutation valve providesgreater, more consistent volumetricefficiency.• Wheel mount version available.

• More starting torque than competitivemotors in applications where the shaft isside loaded. (Competitive brands requiremore pressure to start the motor.)

• A needle-roller mounted coupling shaftand steel-caged thrust bearing which canwithstand 1000-pound thrust loads.

• Side load capacity is 1600 lbs. (727.3 kg)maximum at center of output shaft.

• A unique high-pressure shaft seal thateliminates the need for case drains, checkvalves and extra plumbing.

• Up to 17 horsepower output.

• Greater durability due to superior lubrica-tion and minimum drive spline wear.

• Patented 60-40 spline member arrange-ment transmits more torque with less weight.

Torqmotor™ Design Features

Torqmotor™ TB/TC Series featuresinclude:• The roller vane rotor set design offers alow-friction, wear compensation whichmaximizes the useful performance life of themotor.

• Zero leak commutation valve providesgreater, more consistent volumetricefficiency.• Design flexibility - TB offers the widestselection of shaft options, displacementsand mounting flanges in the industry.

• Patented 60-40 spline member arrange-ment transmits more torque with less weight.

• Full flow lubrication maximizes coolingand may provide up to 50% longer life thanmotors not having this feature.

• Higher pressure rating provide greatertorque than competitive brands.

• Full interchangeability with other motorswhich are designed according to industrystandards.

• Compatible with most hydraulic systemswith regard to pressure, torque and speed.

• A unique high-pressure shaft seal thateliminates the need for case drains.


COUPLING SHAFT

HIGH PRESSURE SEAL

NEEDLE THRUSTBEARING

HOUSING


DIRT & WATER SEAL

BUSHING

MATCHED ROTOR SET




5

COUPLINGSHAFT

HIGH PRESSURE SEAL


HOUSING


DIRT & WATER SEAL

MATCHED ROTOR SET



Torqmotor™ TG/ TH/TL Series featuresinclude:• Roller vanes to reduce friction and internalleakage and to maintain efficiency.

• A patented orbiting commutation system forless wear and longer life.

• A patented 60:40 arrangement of internal andexternal spline members to transmit more torquewith less weight.

• A unique high-pressure shaft seal that elimi-nates the need for case drains, check valves andextra plumbing.

• A manifold designed to improve operatingefficiency.

• Heavy-duty thrust and roller bearings for up totwice the side-load capacity to the previousmotor.

• Up to 1000 lbs. (453.6 kg) end-thrust capacityin either direction.

• A design that is less sensitive to contaminationthan competitive motors.


• Greater durability because of superior lubrica-tion and minimum drive spline wear.

• Zero leak commutation valve providesgreater, more consistent volumetric efficiency.

Torqmotor™ Design FeaturesTorqmotor™ TF Series features include:• Heavy-duty thrust and roller bearings for up totwice side-load capacity to the previous motor.

• Roller vanes to reduce friction and internalleakage, and to maintain efficiency.

• A patented orbiting commutation system forless wear and longer life.

• A patented 60:40 arrangement of internal andexternal spline members to transmit more torquewith less weight.

• A unique high-pressure shaft seal that elimi-nates the need for case drains, check valves andextra plumbing.

• A unique manifold designed to improveoperating efficiency.

• Up to 1000 lbs. (453.6 kg) end-thrust capacityin either direction.

• A design that is less sensitive to contaminationthan competitive motors.


• Greater durability because of superior lubrica-tion and minimum drive spline wear.

• Superior low speed performance.

• Zero leak commutation valve providesgreater, more consistent volumetric efficiency.

COUPLING SHAFT

HIGH PRESSURE SEAL


HOUSING


DIRT & WATER SEAL

MATCHED ROTOR SET



Torqmotor™ Design Features



6



7

Introduction

This service manual has one purpose: to guide you inmaintaining, troubleshooting, and servicing the TC, TB,TE, TJ, TF, TH and TL Torqmotor™ (low-speed, high-torque hydraulic motor).Material in this manual is organized so you can work onthe Torqmotor™ and get results without wasting time orbeing confused. To get these results, you should readthis entire manual before you begin any work on theTorqmotor™.This manual also contains troubleshooting informationand checklist. If you must service the Torqmotor™, thechecklist will help you to determine where the problemmay be.The three-column format of the Disassembly andInspection, and Assembly sections will make it easierfor you to conduct major work on the Torqmotor™.Column 1 gives a brief key for each procedure. Column2 explains in detail the procedure you should follow.Column 3 illustrates this procedure with photographs.Read all material carefully and pay special attention tothe notes, cautions, and warnings.

A page with the Torqmotor™ exploded assembly view isprovided several places in this manual. The componentpart names and item numbers assigned on this ex-ploded assembly view correspond with names and itemnumbers (in parentheses) used in the disassembly andassembly procedures set forth in this manual.Service part list charts are also provided in this manualwith the part names and exploded view item numberscross referenced to Parker service part numbers.Service parts are available through the Original Equip-ment Manufacturer or Parker approved TC, TB, TE, TJ,TF, TH and TL Distributors.As you gain experience in servicing the Torqmotor™, youmay find that some information in this manual could beclearer or more complete. If so, let us know about it. Donot try to second guess the manual. If you are stuck,contact us. Servicing the Torqmotor™ should be a safeand productive procedure, in order for the unit to deliverthe reliable, long-life operation engineered into it.



8

NOTE: Before troubleshooting any system problem, check service literature published by the equipment and/orcomponent manufacturers. Follow their instructions, if given, for checking any component other than theTorqmotor™ unit.

PreparationMake your troubleshooting easier by preparing asfollows:• work in a clean, well-lighted place;• have proper tools and materials nearby;• have an adequate supply of clean petroleum-based

solvent.

WARNING: SINCE SOLVENTS ARE FLAMMABLE, BEEXTREMELY CAREFUL WHEN USING ANY SOL-VENT, EVEN A SMALL EXPLOSION OR FIRE COULDCAUSE INJURY OR DEATH.WARNING: WEAR EYE PROTECTION AND BE SURETO COMPLY WITH OSHA AND OTHER MAXIMUM AIRPRESSURE REQUIREMENTS.

Preliminary ChecksHydraulic systems are often trouble-free. Hence, theproblem an operator complains of could be cause bysomething other than the hydraulic components.Thus, once you have determined that a problem exists,start with the easy-to-check items, such as:• parts damaged from impact that were not properly

repaired, or that should have been replaced; and• improper replacement parts used in previous

servicing• mechanical linkage problems such as binding,

broken, or loose parts or slipping belts

Hydraulic ComponentsIf you think the problem is caused by a hydrauliccomponent, start by checking the easy-to-reach items.Check all hoses and lines for cracks, hardening, orother signs of wear. Reroute any usable hoses that arekinked, severely bent, or that rest against hot engineparts. Look for leaks, especially at couplings andfittings. Replace any hoses or lines that don’t meetsystem flow and pressure ratings.Next, go to the reservoir and filter or filters. Check fluidlevel and look for air bubbles. Check the filter(s). A filterwith a maximum 50 micron filtration is recommended forthe TorqmotorTM system.Visually check other components to see if they areloosely mounted, show signs of leaks, or other damageor wear.Excessive heat in a hydraulic system can createproblems that can easily be overlooked. Every systemhas its limitation for the maximum amount of tempera-ture. After the temperature is attained and passed, thefollowing can occur:• oil seal leaks• loss of efficiency such as speed and torque• pump loss of efficiency• pump failure• hoses become hard and brittle• hose failure

A normal temperature range means an efficient hydrau-lic system. Consult the manuals published by equip-ment and/or component manufacturers for maximumallowable temperature and hydraulic tests that may benecessary to run on the performance of the hydrauliccomponents. The Torqmotor™ is not recommended forhydraulic systems with maximum temperatures above200°F (93.3°C).

Troubleshooting Guide



9

Troubleshooting Checklist

1. Hose fittings loose, worn ordamaged.

2.Oil seal rings (4) deteriorated byexcess heat.

3.Special bolt (1, 1A, 1B or 1C)loose or its sealing areadeteriorated by corrosion.

4.Internal shaft seal (16) worn ordamaged.

5.Worn coupling shaft (12) andinternal seal (16).

Oil Leakage Check & replace damagedfittings or “O” Rings. Torque tomanufacturers specifications.

Replace oil seal rings by disassemblingTorqmotor™ unit.

(a) Loosen then tighten single bolt totorque specification.

(b) Replace bolt.

Replace seal. Disassembly of Torqmotor™unit necessary.

Replace coupling shaft and seal bydisassembling Torqmotor™ unit.

Significant loss ofspeed under load

1. Lack of sufficient oil supply

2.High internal motor leakage

3.Severely worn or damagedinternal splines.

4.Excessive heat.

(a) Check for faulty relief valve andadjust or replace as required.

(b) Check for and repair worn pump.

(c) Check for and use correct oil fortemperature of operation.

Replace worn rotor set by disassemblingTorqmotor™ unit.

Replace rotor set, drive link and couplingshaft by disassembling Torqmotor™ unit.

Locate excessive heat source (usually arestriction) in the system and correct thecondition.

Low mechanicalefficiency or unduehigh pressurerequired to operateTorqmotor™ unit

1. Line blockage

2.Internal interference

3.Lack of pumping pressure

4.Excessive binding or loading insystem external to Torqmotor™unit.

Locate blockage source and repair orreplace.

Disassemble Torqmotor™ unit, identify andremedy cause and repair, replacing parts asnecessary.

Check for and repair worn pump.

Locate source and eliminate cause.

CAUTION: If the hydraulic system fluid becomes overheated [in excess of 200°F (93.3°C)], seals in the systemcan shrink, harden or crack, thus losing their sealing ability.

Trouble Cause Remedy



10

• Clean, petroleum-based solvent• Emery paper• Vise with soft jaws• Air pressure source• Arbor press• Screw driver• Masking tape• Breaker bar• Torque wrench-ft. lbs. (N m)• Sockets: 1/2 or 9/16 inch thin wall, 1 inch• Allen Sockets: 3/16, 3/8 inch• Adjustable crescent wrench or hose fitting wrenches• SAE 10W40 SE or SF oil• Special bearing mandrel for TC, TB & TE Torqmotors (SEE FIGURE 1)• Special bearing mandrel for TH Torqmotors (consult factory)• Special bearing mandrel for TF, TG & TJ Torqmotors (SEE FIGURE 2)• Feeler gage .005 inch (.13 mm)• TC, TB & TE Torqmotors require blind hole bearing puller for 1.06 inch (26.9) mm) and 1.62 inch (41.1 mm)

diameter bearing/bushing.• TH Torqmotors require blind hole bearing puller for a 1.575 inch dia. (40.0 mm) and 2.130 inch dia. (54.1 mm)

bearings.• TJ, TF, TG & TL Torqmotors require blind hole bearing puller for 1.400 inch dia. (35.6 mm) and 2.130 inch dia. (54.1

mm) bearings.• Clean corrosion resistant grease. Part #406018 is included in each seal kit. Recommended grease is Parker

Specification #045236 or Mobil Mobilith SHC® 460

NOTE: The available service seal kits include the recommended grease as a grease pack #406018

CAUTION: Mixing greases that have different bases can be detrimental to bearing life.

Tools and Materials Required for Servicing



11

CONVERSIONSINCHES mm INCHES mm

.020 .51 1.060 26.92

.021 .53 1.295 32.89

.029 .74 1.297 32.94

.030 .76 1.396 35.46

.111 2.81 1.398 35.51

.119 3.02 1.620 41.15

.152 3.86 1.622 41.20

.160 4.06 1.983 50.37

.296 7.52 1.985 50.42

.304 7.72 2.120 53.85

.460 11.68 2.122 53.90

.470 11.94 2.233 56.72

.500 12.70 2.235 56.77

.585 14.86 2.483 63.07

.595 15.11 2.485 63.12

.660 16.76 2.500 63.5

.675 17.15 2.88 73.21.058 26.87

Torque ChartPart Name Item Number Torquebolt 5/16 24 UNF 2A 1, 1A, 1B or 1C 22-26 ft. lbs. (30-35 N m)bolt 3/8 24 UNF 2A 1, 1A, 1B or 1C 45-55 ft. lbs. (60-76 N m)bolt 5/8 18 UNF 2A 12D 140-180 ft. lbs. (190-244 N m)nut 3/4 16 UNF 2B 12B (TC, TB, TE) 175-255 ft. lbs. (237-305 N m)nut 1-20 UNEF 2B 12B (TF, TG, TL) 300-400 ft. lbs. (407-542 N m)nut 1-1/8 18 UNEF 2B 12B (TG, TH) 300-400 ft. lbs. (407-542 N m)

(Fabricate if considered necessary)Figure 1 – TC, TB & TE

(Fabricate if considered necessary)Figure 2 – TF & TG (see note)

Technical Information

- TC has two steel bushing internal of housing press first steel bushing 1.223 deep

from housing face the second steel bushing press .03 below face

- TL press internal bearing .576 below face.



28

Preparation Before Disassembly

• Before you disassemble the Torqmotor™ unit or any of its components read this entire manual. It providesimportant information on parts and procedures you will need to know to service the Torqmotor™.

• Determine whether the Torqmotor™ you are about to disassemble is the Small Frame Series TC, TB, TE or TJ orthe Large Frame Series TF, TG, TL or TH so you can follow those procedures that pertain to that SeriesTorqmotor™. The first two letters of the “spec” number on the Torqmotor™ identification tag is the Series designa-tion. Also determine the type of end construction from the alternate views shown on the exploded view.

• The Small Frame Series TC, TB & TE Torqmotors™ will have a 3.66 inch (92.9 mm) main body outside diameterand five or six 5/16-24 UNF 2A cover bolts. The Medium Frame Series TJ Torqmotors™ will have a 3.66 inch (92.9mm) main body outside diameter and six 5/16-24 UNF 2A cover bolts. The Large Frame Series TF, TG, TL & THTorqmotors™ will have a 5 inch (127.9 mm) main body outside diameter and seven 3/8 24 UNF 2A cover bolts.

• Refer to “Tools and Materials Required for Services” section for tools and other items required to service theTorqmotor™ and have them available.

• Thoroughly clean off all outside dirt, especially from around fittings and hose connections, before disconnectingand removing the Torqmotor™. Remove rust or corrosion from coupling shaft.

• Remove coupling shaft connections and hose fittings and immediately plug port holes and fluid lines.

• Remove the Torqmotor™ from system, drain it of fluid and take it to a clean work surface.

• Clean and dry the Torqmotor™ before you start to disassemble the unit.

• As you disassemble the Torqmotor™ clean all parts, except seals, in clean petroleum-based solvent, and blowthem dry.

WARNING: petroleum-base solvents are flammable. Be extremely careful when using any solvent. Even a smallexplosion or fire could cause injury or death.

WARNING: WEAR EYE PROTECTION AND BE SURE TO COMPLY WITH OSHA OR OTHER MAXIMUM AIRPRESSURE REQUIREMENTS.

CAUTION: Never steam or high pressure wash hydraulic components. Do not force or abuse closely fitted parts.

• Keep parts separate to avoid nicks and burrs.

• Discard all seals and seal rings as they are removed from the Torqmotor™. Replace all seals, seal rings and anydamaged or worn parts with genuine Parker or OEM approved service parts.

Disassembly and Inspection



29


PlaceTorqmotorin a vise

1. Place the Torqmotor™ in a soft jawed vice,with coupling shaft (12) pointed down and thevise jaws clamping firmly on the sides of thehousing (18) mounting flange or port bosses.Remove manifold port O-Rings (18A) ifapplicable.

WARNING WARNING: IF THE TORQMOTOR™ IS NOTFIRMLY HELD IN THE VISE, IT COULD BEDISLODGED DURING THE SERVICEPROCEDURES, CAUSING INJURY.

Scribe alignmentmark & loosevalve plugs

2. Scribe an alignment mark down and acrossthe Torqmotor™ components from end cover(2) to housing (18) to facilitate reassemblyorientation where required. Loosen two shuttleor relief valve plugs (21) for disassembly laterif included in end cover. 3/16 or 3/8 inch Allenwrench or 1 inch hex socket required. SEEFIGURES 3 & 4.

Remove specialbolts &inspect bolts

3. Remove the five, six, or seven special ringhead bolts (1, 1A, 1B, or 1C) using anappropriate 1/2 or 9/16 inch size socket. SEEFIGURE 5. Inspect bolts for damagedthreads, or sealing rings, under the bolt head.Replace damaged bolts. SEE FIGURE 6.

Reference Exploded Assembly View

Figure 6

Figure 5

Figure 4

Figure 3



30

Remove endcover &inspect bolts

NOTE

Remove plugsand valves

4. Remove end cover assembly (2) and sealring (4). Discard seal ring. SEE FIGURE 7.

NOTE: Refer to the appropriate “alternatecover construction” on the exploded viewto determine the end cover constructionbeing serviced.

5. If the end cover (2) is equipped with shuttlevalve or relief valve (24) components,remove the two previously loosened plugs(21) and o-rings (22). SEE FIGURE 8.

CAUTION

NOTE

NOTE

CAUTION: Be ready to catch the shuttlevalve or relief valve components that willfall out of the end cover valve cavity whenthe plugs are removed.

NOTE: O-ring (22) is not included in sealkits but serviced separately if required.

NOTE: The insert and if included theorifice plug in the end cover (2) must notbe removed as they are serviced as anintegral part of the end cover.

Wash & inspectend cover

NOTE

6. Thoroughly wash end cover (2) in propersolvent and blow dry. Be sure the end covervalve apertures, including the internal orificeplug, are free of contamination. Inspect endcover for cracks and the bolt head recessesfor good bolt head sealing surfaces. Replaceend cover as necessary. SEE FIGURE 9.

NOTE: A polished pattern (not scratches)on the cover from rotation of the commu-tator (5) is normal. Discoloration wouldindicate excess fluid temperature, thermalshock, or excess speed and requiresystem investigation for cause and closeinspection of end cover, commutator,manifold, and rotor set.

Remove &inspectcommutatorring

7. Remove commutator ring (6). SEE FIGURE 10.Inspect commutator ring for cracks, or burrs.

Figure 10

Figure 9

Figure 8

Figure 7




31

Remove &inspectcommutator

8. Remove commutator (5) and seal ring (3)Remove seal ring from commutator, using anair hose to blow air into ring groove until sealring is lifted out and discard seal ring. Inspectcommutator for cracks or burrs, wear, scoring,spalling or brinelling. If any of these conditionsexist, replace commutator and commutatorring as a matched set. SEE FIGURE 11 & 12.

Removemanifold

9. Remove manifold (7) and inspect for crackssurface scoring, brinelling or spalling. Replacemanifold if any of these conditions exist. SEEFIGURE 13. A polished pattern on the groundsurface from commutator or rotor rotation isnormal. Remove and discard the seal rings (4)that are on both sides of the manifold.

NOTE NOTE: The manifold is constructed of platesbonded together to form an integral compo-nent not subject to further disassembly forservice. Compare configuration of both sidesof the manifold to ensure that same surface isreassembled against the rotor set.

Remove &inspectrotor set &wearplate

10. Remove rotor set (8) and wearplate (9),together to retain the rotor set in its assembledform, maintaining the same rotor vane (8C) tostator (8B) contact surfaces. SEE FIGURE 14.The drive link (10) may come away from thecoupling shaft (12) with the rotor set, andwearplate. You may have to shift the rotor seton the wearplate to work the drive link out ofthe rotor (8A) and wearplate. SEE FIGURE 15.Inspect the rotor set in its assembled form fornicks, scoring, or spalling on any surface andfor broken or worn splines. If the rotor setcomponent requires replacement, the completerotor set must be replaced as it is a matchedset. Inspect the wearplate for cracks, brinelling,or scoring. Discard seal ring (4) that is betweenthe rotor set and wearplate.

NOTE NOTE: The rotor set (8) components maybecome disassembled during serviceprocedures. Marking the surface of the rotorand stator that is facing UP, with etching inkor grease pencil before removal fromTorqmotor™ will ensure correct reassemblyof rotor into stator and rotor set intoTorqmotor™. Marking all rotor componentsand mating spline components for exactrepositioning at assembly will ensuremaximum wear life and performance ofrotor set and Torqmotor™.

Figure 11

Figure 12

Figure 13

Figure 14




32

NOTE NOTE: Series TG or TH may have a rotor setwith two stator halves (8B & 8D) with a sealring (4) between them and two sets of sevenvanes (8C & 8E). Discard seal ring only ifstator halves become disassembled duringthe service procedures.

NOTE NOTE: A polished pattern on the wearplate from rotor rotation is normal.

Check rotor,vance clearance

11. Place rotor set (8) and wear plate (9) on a flatsurface and center rotor (8A) in stator (8B)such that two rotor lobes (180 degrees apart)and a roller vane (8C) centerline are on thesame stator centerline. Check the rotor lobeto roller vane clearance with a feeler gage atthis common centerline. If there is more than.005 inches (0.13 mm) of clearance, replacerotor set. SEE FIGURE 16.

NOTE NOTE: If rotor set (8) has two stator halves(8B & 8D) and two sets of seven vanes (8C& 8E) as shown in the alternate construc-tion TG rotor set assembly view, check therotor lobe to roller vane clearance at bothends of rotor.

Remove &inspectdrive link

12. Remove drive link (10) from coupling shaft(12) if it was not removed with rotor set andwear plate. Inspect drive link for cracks andworn or damaged splines. No perceptible lash(play) should be noted between mating splineparts. SEE FIGURE 17. Remove and discardseal ring (4) from housing (18).

Remove thrustbearing

13. Remove thrust bearing (11) from top ofcoupling shaft (12) if Torqmotor is a SeriesTF, TG, TH or TL. Inspect for wear, brinelling,corrosion and a full complement of retainedrollers. SEE FIGURE 18.

Figure 18

Figure 17

Figure 16

Figure 15




33

Check couplingshaft for rustor corrosion

14. Check exposed portion of coupling shaft (12)to be sure you have removed all signs of rustand corrosion which might prevent itswithdrawal through the seal and bearing.Crocus cloth or fine emery paper may beused. SEE FIGURE 19. Remove any key(12A), nut (12B), washer (12C), bolt (12D),lock washer (12E), or retaining ring (12F).

Remove &inspectcoupling shaft

15. Remove coupling shaft (12), by pushing onthe output end of shaft. SEE FIGURE 20.Inspect coupling shaft bearing and sealsurfaces for spalling, nicks, grooves, severewear or corrosion and discoloration. Inspectfor damaged or worn internal and externalsplines or keyway. SEE FIGURE 21. Replacecoupling shaft if any of these conditionsexist.

NOTE

NOTE

NOTE: Minor shaft wear in seal area ispermissible. If wear exceeds .020 inches(0.51 mm) diametrically, replace couplingshaft.

NOTE: A slight “polish” is permissible inthe shaft bearing areas. Anything morewould require coupling shaft replacement.

Remove sealring fromhousing

16. Remove and discard seal ring (4) fromhousing (18).

Remove &inspect thrustwasher &thrust bearing

NOTE

17. Remove thrust bearing (15) and thrust washer(14) if the unit is a Series TC, TB or TE.Inspect for wear, brinelling, corrosion and a fullcomplement of retained rollers. SEE FIGURE22. Note: The TL motor has only one thrustbearing and washer.

NOTE: Large Frame Series TF, TG & TJTorqmotors have a thrust bearing (15)sandwiched between two thrust washers(14) that cannot be removed from housing(18) unless bearing (13) is removed forreplacement. Figure 22

Figure 21

Figure 20

Figure 19




34

Remove seal& washer orwashers

18. Remove seal (16) and back up ring (17) fromSmall Frame, TC, TB & TE housing (18) andbackup washer (25). Discard both. SEEFIGURE 23.

Remove seal (16), backup ring (17), andbackup washer (25) from Large Frame, SeriesTF, TG, TJ and TH housing by working themaround unseated thrust washers (14) and thrustbearing (15) and out of the housing. Discardseal and washers. SEE FIGURE 24.

NOTE NOTE: The original design units of Large& Small Frame Torqmotors™ did notinclude backup washer (25), but mustinclude backup washer (25) when reas-sembled for service.

Remove seal 19. Remove housing (18) from vise, invert it andremove and discard seal (20). A blind holebearing or seal puller is required.SEE FIGURE 25.

Inspecthousingassembly

20. Inspect housing (18) assembly for cracks,the machined surfaces for nicks, burrs,brinelling or corrosion. Remove burrs that canbe removed without changing dimensionalcharacteristics. Inspect tapped holes forthread damage. SEE FIGURE 26. If thehousing is defective in these areas, discardthe housing assembly.

Figure 23

Figure 24

Figure 25

Figure 26




35

Inspect housingbearing/bushing

21. If the housing (18) assembly has passedinspection to this point, inspect the housingbearings/bushings (19) and (13) and if theyare captured in the housing cavity the twothrust washers (14) and thrust bearing (15).The bearing rollers must be firmly retained inthe bearing cages, but must rotate and orbitfreely. All rollers and thrust washers must befree of brinelling and corrosion. SEE FIGURE27. The TB Series bushing (19) or (13) tocoupling shaft diameter clearance must notexceed .010 inch (.025 mm). A bearing,bushing, or thrust washer that does not passinspection must be replaced. SEE FIGURE28. If the housing has passed this inspectionthe disassembly of the Torqmotor™ iscompleted.

NOTE NOTE: The depth or location of bearing/bushing (13) in relation to the housingwear plate surface and the depth orlocation of bearing/bushing (19) in rela-tion to the beginning of bearing/bushingcounter bore should be measured andnoted before removing the bearings/bushings. This will facilitate the correctreassembly of new bearings/bushings.SEE FIGURE 29.

Removebearingsor bushings& thrustwashers

22. If the bearings, bushing or thrust washersmust be replaced use a suitable size bearingpuller to remove bearing/bushings (19) and(13) from housing (18) without damaging thehousing. Remove thrust washers (14) andthrust bearing (15) if they were previouslyretained in the housing by bearing (13). SEEFIGURES 30 & 31.

THE DISASSEMBLY OF TORQMOTOR™ IS COMPLETED.

Figure 27

Figure 28

Figure 29

Figure 30

Figure 31




36

• Replace all seals and seal rings with new ones each time you reassemble the Torqmotor™ unit. Lubricate allseals and seal rings with SAE 10W40 oil or clean grease before assembly.

• NOTE: Individual seals and seal rings as well as a complete seal kit are available. SEE FIGURE 32. Theparts should be available through most OEM parts distributors or Parker approved Torqmotor™ dis-tributors. (Contact your local dealer for availability).

• NOTE: Unless otherwise indicated, do not oil or grease parts before assembly.

• Wash all parts in clean petroleum-based solvents before assembly. Blow them dry with compressed air. Removeany paint chips from mating surfaces of the end cover, commutator set, manifold rotor set, wear plate andhousing and from port and sealing areas.

WARNING

WARNING

WARNING: SINCE THEY ARE FLAM-MABLE, BE EXTREMELY CAREFUL WHENUSING ANY SOLVENT. EVEN A SMALLEXPLOSION OR FIRE COULD CAUSEINJURY OR DEATH.

WARNING: WEAR EYE PROTECTION ANDBE SURE TO COMPLY WITH OSHA OROTHER MAXIMUM AIR PRESSURE RE-QUIREMENTS.

Press in outerbearing/bushing

1. If the housing (18) bearing components wereremoved for replacement, thoroughly coat andpack a new outer bearing/bushing (19) withclean corrosion resistant grease recommendedin the material section. Press the new bearing/bushing into the counterbore at the mountingflange end of the housing, using the appropri-ate sized bearing mandrel such as described infigure 1 or figure 2 which will control thebearing/ bushing depth.

Small Frame Series TB and TE Torqmotor™housings require the use of bearing mandrelshown in figure 1 to press bearing/ bushing(19) into the housing to a required depth of.151/.161 inches (3.84/4.09 mm) from the endof the bearing counterbore. SEE FIGURE 33.(TC reference page 10).

Large Frame Series TF, TG & TJ Torqmotor™housings require the use of the bearingmandrel shown in figure 2 to press bearing (19)into the housing to a required depth of .290/.310 inches (7.37/7,87 mm) from the outsideend of the bearing counterbore.SEE FIGURE 34.

Large Frame Series TH Torqmotor housingsrequire the use of a bearing mandrel. Consultfactory for specifications.

Figure 32, TF, TG seal kit

Figure 33

Figure 34

Torqmotor™ Assembly



37

NOTE NOTE: Bearing mandrel must be pressedagainst the lettered end of bearing shell.Take care that the housing bore is squarewith the press base and the bearing/bushing is not cocked when pressing abearing/bushing into the housing.

CAUTION CAUTION: If the bearing mandrel specifiedin the “Tools and Materials Required forServicing” section is not available andalternate methods are used to press inbearing/bushing (13) and (19) the bearing/bushing depths specified must beachieved to insure adequate bearingsupport and correct relationship toadjacent components when assembled.SEE FIGURE 35.

CAUTION CAUTION: Because the bearing/bushings(13) and (19) have a press fit into thehousing they must be discarded whenremoved. They must not be reused.

Press in innerbearing/bushing

2. The Small Frame Series TB and TETorqmotor™ inner housing bearing/bushing (13)can now be pressed into its counterbore inhousing (18) flush to .03 inch (.76 mm) belowthe housing wear plate contact face. Use theopposite end of the bearing mandrel that wasused to press in the outer bearing/bushing (19).Reference figure 1, “Tools and MaterialsRequired for Servicing” section. SEE FIGURE36.

The Large Frame Series TF, TG & TJTorqmotor™ housing (18) requires that youassemble a new backup washer (25) &backup ring (17), new seal (16), with the lipfacing to the inside of Torqmotor (see figure69A), new thrust washer (14), new thrustbearing (15) and a new second thrust washer(14) in that order before pressing in the innerhousing bearing (13). SEE FIGURE 37 & 38.When these components are in place, pressnew bearing (13) into the housing (18) to adepth of .105/.125 inches (2.67/3.18), .03inches max for TJ (.76) below the housingwear plate contact face. Use the oppositeend of the bearing mandrel used to press inouter bearing (19). Reference figure 2, in the“Tools and Materials Required for Servicing”section. SEE FIGURE 39.

Figure 35

Figure 36

Figure 37

Figure 38




38

Press in dirt &water seal

3. Press a new dirt and water seal (20) into thehousing (18) outer bearing counterbore.

The Small Frame Series TC, TB and TETorqmotor™ dirt and water seal (20) must bepressed in until its’ flange is flush against thehousing. SEE FIGURE 40.

The Large Frame Series TF, TG, TJ & THTorqmotor™ dirt and water seal (20) must bepressed in with the lip facing out and until theseal is flush to .020 inches (.51 mm) belowthe end of housing. SEE FIGURE 41.

4. Place housing (18) assembly into a softjawed vise with the coupling shaft bore down,clamping against the mounting flange. SEEFIGURE 42.

Place housingassemblyinto vice

Figure 42

Figure 41

Figure 40

Figure 39




39

Assemble backupwasher & seal

5. On Small Frame, Series TC, TB & TETorqmotors™ assemble a new backup ring(17), new bakcup washer (25) and new seal(16) with the seal lip facing toward the insideof Torqmotor™ (see Figure 69B), into theirrespective counterbores in housing (18) ifthey were not assembled in procedure 2.

Large Frame, Series TF, TG, TJ & THTorqmotor™ housing (18) that did not requirereplacement of the bearing package willrequire that the two “captured” thrust washers(14) and thrust bearing (15) be unseated andvertical to the counterbore and the newbackup ring (17), new backup washer (25),and new seal (16) be worked around thethrust bearing package and placed into theirrespective counterbores. The seal lip mustface out of the seal counterbore and towardthe inside of Torqmotor™ (see figure 69A). Besure the thrust bearing package is reseatedcorrectly after assembly of the seal andbackup washer. SEE FIGURES 43 & 44.

CAUTION CAUTION: Original design Large Frame, TF& TG Torqmotors™ that do not havebackup washer (25) when disassembledmust be assembled with a new backupring (17), new backup washer (25), andnew seal (16).

Assemble thrustwasher & bearing

NOTE

6. Assemble thrust washer (14) then thrustbearing (15) that was removed from the SeriesTB or TE Torqmotor™. SEE FIGURE 45.

NOTE: Small Frame Series TC, TB and TETorqmotors™ require one thrust washer(14) with thrust bearing (15). The couplingshaft will be seated directly against thethrust bearing.

Apply maskingtape to shaft

7. Apply masking tape around splines orkeyway on shaft (12) to prevent damage toseal. SEE FIGURE 46.

Figure 46

Figure 45

Figure 44

Figure 43




40

Installcouplingshaft

8. Be sure that a generous amount of cleancorrosion resistant grease has been applied tothe lower (outer) housing bearing/bushing (19).Install the coupling shaft (12) into housing (18),seating it against the thrust bearing (15) in TC,TB and TE Series housings and against thesecond thrust washer (14) in TF and TG Serieshousings. SEE FIGURE 47.

CAUTION

NOTE

CAUTION: The outer bearing (19) is notlubricated by the system’s hydraulic fluid.Be sure it is thoroughly packed with therecommended grease, Parker Gear greasespecification #045236, E/M Lubricant#K-70M.

NOTE: Mobil Mobilith SHC ® 460NOTE: A 102 Tube (P/N 406010) is includedin each seal kit.

NOTE NOTE: The coupling shaft (12) will be flushor just below the housing wear surface onSmall Frame, Series TC, TB, TE & TJTorqmotors™ when properly seated whilethe coupling shaft (12) on Large Frame,Series TF, TG, or TH Torqmotors™ will beapproximately .10 inch (2.54 mm) below thehousing wear plate surface to allow theassembly of thrust bearing (11). The cou-pling shaft must rotate smoothly on thethrust bearing package. SEE FIGURE 48.

Install thrustbearing

9. Install thrust bearing (11) onto the end ofcoupling shaft (12) only if you are servicing anTF, TG, TH or TL Series Torqmotor™.SEE FIGURE 49.

Insert sealring

10. Apply a small amount of clean grease to anew seal ring (4) and insert it into the housing(18) seal ring groove. SEE FIGURE 50.

NOTE NOTE: One or two alignment studsscrewed finger tight into housing (18) boltholes, approximately 180 degrees apart,will facilitate the assembly and alignmentof components as required in the follow-ing procedures. The studs can be made bycutting off the heads of either3/8-24 UNF 2A or 5/16-24 UNF 2A bolts asrequired that are over .5 inch (12.7 mm)longer than the bolts (1, 1A, 1B, or 1C)used in the Torqmotor™.

Figure 47

Figure 48

Figure 49

Figure 50




41

Installdrive link

NOTE

11. Install drive link (10) the long splined enddown into the coupling shaft (12) and engagethe drive link splines into mesh with thecoupling shaft splines. SEE FIGURE 51.

NOTE: Use any alignment marks put onthe coupling shaft and drive link beforedisassembly to assemble the drive linksplines in their original position in themating coupling shaft splines.

Assemblewear plate

12. Assemble wear plate (9) over the drive link(10) and alignment studs onto the housing(18). SEE FIGURE 52.

Assembleseal ring

13. Apply a small amount of clean grease to anew seal ring (4) and assemble it into theseal ring groove on the wear plate side of therotor set stator (8B). SEE FIGURE 53.

Install theassembledrotor set

14. Install the assembled rotor set (8) onto wearplate (9) with rotor (8A) counterbore and sealring side down and the splines into mesh withthe drive link splines. SEE FIGURE 54.

NOTE NOTE: It may be necessary to turn onealignment stud out of the housing (18)temporarily to assemble rotor set (8) ormanifold (7) over the drive link.

NOTE NOTE: If necessary, go to the appropriate,“Rotor Set Component AssemblyProcedure.”

NOTE NOTE: The rotor set rotor counterbore sidemust be down against wear plate for drivelink clearance and to maintain the originalrotor-drive link spline contact. A rotor setwithout a counterbore and that was notetched before disassembly can be rein-stalled using the drive link spline patternon the rotor splines if apparent, to deter-mine which side was down. The rotor setseal ring groove faces toward the wearplate (9).

Figure 51

Figure 52

Figure 53

Figure 54




42

Assembleseal ringin manifold

NOTE

15. Apply clean grease to a new seal ring (4) andassemble it in the seal ring groove in therotor set contact side of manifold (7). SEEFIGURE 55.

NOTE: The manifold (7) is made up ofseveral plates bonded together perma-nently to form an integral component. Themanifold surface that must contact therotor set has it’s series of irregular shapedcavities on the largest circumference orcircle around the inside diameter. Thepolished impression left on the manifoldby the rotor set is another indication ofwhich surface must contact the rotor set.

Assemblemanifold

16. Assemble the manifold (7) over the alignmentstuds and drive link (10) and onto the rotorset. Be sure the correct manifold surface isagainst the rotor set. SEE FIGURE 56.

Insert a sealin manifold

17. Apply grease to a new seal ring (4) andinsert it in the seal ring groove exposed onthe manifold. SEE FIGURE 57.

Assemblecommutator ring

18. Assemble the commutator ring (6) overalignment studs onto the manifold. SEEFIGURE 58.

Figure 55

Figure 56

Figure 57

Figure 58




43

Assembleseal &commutator

19. Assemble a new seal ring (3) flat side up,into commutator (5) and assemble commuta-tor over the end of drive link (10) ontomanifold (7) with seal ring side up. SEEFIGURE 59, 60.

Assemble shuttlevalve parts intoend cover

20. If shuttle valve components items #21, #22,#23, #24 were removed from the end cover(2) turn a plug (21) with a new o-ring (22),loosely into one end of the valve cavity in theend cover. Insert a spring (23) the valve (24)and the second spring (23) into the other endof the valve cavity. Turn the second plug (21)with a new o-ring (22) loosely into the endcover valve cavity. 3/16 inch Allen wrenchrequired. SEE FIGURE 61.

Assemble reliefvalve parts inend cover

21. If relief valve components items #21, #22,#24 were removed from the end cover (2)assemble a new o-ring (22) on the two plugs(21). Assemble a two piece relief valve (24) ineach of the plugs, with the large end of theconical spring into the plug first and the smallnut of the other valve piece in the small endof the conical spring. Turn each of the plugand relief valve assemblies into the endcover loosely to be torqued later. 3/8 inchAllen or 1 inch Hex socket required. SEEFIGURE 62.

Figure 59

Figure 60

Figure 61

Figure 62




44

Assemble sealring &end cover

22. Assemble a new seal ring (4) into end cover(2) and assemble end cover over the align-ment studs and onto the commutator set.SEE FIGURE 63, 64. If the end cover hasonly 5 bolt holes be sure the cover holes arealigned with the 5 threaded holes in housing(18). The correct 5 bolt end cover bolt holerelationship to housing port bosses is shownin FIGURE 65.

NOTE NOTE: If the end cover has a valve (24) orhas five bolt holes, use the line youpreviously scribed on the cover to radiallyalign the end cover into its originalposition.

Assemblecover bolts

23. Assemble the 5, 6 or 7 special bolts (1, 1A,1B or 1C) and screw in finger tight. Removeand replace the two alignment studs withbolts after the other bolts are in place.Alternately and progressively tighten thebolts to pull the end cover and other compo-nents into place with a final torque of 22-26 ft.lbs. (30-35 N m) for the five TC, TB or six TESeries 5/16 24 threaded bolts or six TJ boltsor 45-55 ft. lbs. (61-75 N m) for the seven TF,TG & TL Series 3/8-24 threaded bolts. SEEFIGURE 66, 67, 68.

Figure 63

Figure 64

Figure 65

Figure 66




45

NOTE NOTE: The special bolts required for usewith the relief or shuttle valve (24) endcover assembly (2) are longer than thebolts required with standard and coverassembly. Refer to the individual serviceparts lists or parts list charts for correctservice part number if replacement isrequired.

Torque thevalve plugs

24. Torque the two shuttle valve plug assemblies(21) in end cover assembly to 9-12 ft. lbs.(12-16 N m) if cover is so equipped. SEEFIGURE 69.

Torque the two relief valve plug assemblies(21) in end cover assembly to 45-55 ft. lbs.(61-75 N m) if cover is so equipped.

THE ASSEMBLY OF THE TORQMOTOR™ IS NOW COMPLETE EXCEPT FOR WOODRUFF KEY (12A), NUT(12B), WASHER (12C), BOLT (12D), LOCKWASHER (12E), RETAINER RING (12F) or PORT O-RINGS (18A) ATINSTALLATION IF APPLICABLE. PROCEED TO FINAL CHECKS SECTION.

Figure 69A Large Frame Figure 69B Small Frame

HousingThrustWashers

Seal

Shaft

ThrustBearing

BackupRing

BackupWasher

Not To Scale

HousingThrustWashers

Seal

Shaft

ThrustBearing

BackupRing

Not To Scale

Backup Washer

Figure 69

Figure 68

Figure 67




46

One Piece Stator Construction

A disassembled rotor (8A) stator (8B) and vanes (8C) that cannot be readily assembled by hand can be assembledby the following procedures.

Assemble stator 1. Place stator (8B) onto wear plate (9) with sealring (4) side down, after following Torqmotor™assembly procedures 1 through 13. Be surethe seal ring is in place. SEE FIGURE 70.

Inserttwo bolts

2. If assembly alignment studs are not beingutilized, align stator bolt holes with wear plateand housing bolt holes and turn two bolts (1)finger tight into bolt holes approximately 180degrees apart to retain stator and wear platestationary.

Assemble rotor 3. Assemble the rotor (8A), counterbore down ifapplicable, into stator (8B), and onto wearplate (9) with rotor splines into mesh withdrive link (10) splines. SEE FIGURE 71.

NOTE NOTE: If the manifold side of the rotor wasetched during Torqmotor disassembly,this side should be up. If the rotor is notetched and does not have a counterbore,use the drive link spline contact patternapparent on the rotor splines to determinethe rotor side that must be against thewear plate.

Assemble vanes

CAUTION

Assemble fullcomplementof vanes

Remove twoassembled bolts

4. Assemble six vanes (8C), or as many vanesthat will readily assemble into the stator vanepockets. SEE FIGURE 72.

CAUTION: Excessive force used to push therotor vanes into place could shear off thecoating applied to the stator vane pockets.

5. Grasp the output end of coupling shaft (12)with locking pliers or other appropriateturning device and rotate coupling shaft, drivelink and rotor to seat the rotor and theassembled vanes (8C) into stator (8B),creating the necessary clearance to as-semble the seventh or full complement ofseven vanes. Assemble the seven vanesusing minimum force. SEE FIGURE 73.

6. Remove the two assembled bolts (1) if usedto retain stator and wear plate.

Go to Torqmotor™ assembly procedure #15,to continue Torqmotor™ assembly. Figure 73

Figure 72

Figure 71

Figure 70

Rotor Set Component Assembly



47

Two Piece Stator Construction

A disassembled rotor set (8) that cannot be readily assembled by hand and has a two piece stator can beassembled by the following procedures.

Assemblestator halves

1. Place stator half (8B) onto wear plate (9) withseal ring (4) side down, after followingTorqmotor™ assembly procedures 1 through 13.Be sure the seal ring is in place.

Insert twoalignmentstuds

2. Align stator bolt holes with wear plate andhousing bolts and turn two alignment studs fingertight into bolt holes approximately 180 degreesapart to retain stator half and wear plate station-ary.

Assemble rotor

NOTE

3. Assemble rotor (8A), counterbore down if appli-cable, into stator half (8B), and onto wear plate(9) with rotor splines into mesh with drive link (10)splines.

NOTE: Use any marking you applied to rotorset components to reassemble the compo-nents in their original relationship to ensureultimate wear life and performance.

Assemble vanes

CAUTION

4. Assemble six vanes (8C), or as many vanes thatwill readily assemble into the stator vane pockets.

CAUTION: Excessive force used to push therotor vanes into place could shear off thecoating applied to the stator vane pockets.


5. Grasp the output end of coupling shaft (12) withlocking pliers or other appropriate turning deviceand rotate coupling shaft, drive link and rotor toseat the rotor and the assembled vanes (8C) intostator half (8B), creating the necessary clearanceto assemble the seventh or full complement ofseven vanes. Assemble the seven vanes usingminimum force.

Assemble sealring in statorhalf

6. Place second stator half (8D) on a flat surfacewith seal ring groove up. Apply a small amount ofgrease to a new seal ring (4) and assemble it intostator half ring groove.




48

Assemble secondstator half

7. Assemble the second stator half (8D) over thetwo alignment studs and rotor (8A) with seal ringside down onto the first stator half (8B) aligningany timing marks applied for this purpose.

CAUTION CAUTION: If the stator half (8B) is a differentheight (thickness) than stator half (8D) thestator vanes (8C) or (8E) of the same length(height) as the stator half must be reas-sembled in their respective stator half for therotor set to function properly.

Assemble vanes 8. Assemble six vanes (8E), or as many vanes thatwill readily assemble into the stator vane pockets.


9. Grasp the output end of coupling shaft (12) withlocking pliers or other appropriate turning deviceand rotate coupling shaft, drive link and rotor toseat the rotor and the assembled vanes (8E) intostator (8D), creating the necessary clearance toassemble the seventh or full complement ofseven vanes. Assemble the seven vanes usingminimum force.

Go to Torqmotor™ assembly procedure #15, tocontinue Torqmotor™ assembly.




49

Final Checks• Pressurize the Torqmotor™ with 100 p.s.i. dry air or nitrogen and submerge in solvent to check for

external leaks.

• Check Torqmotor™ for rotation. Torque required to rotate coupling shaft should not be more than50 ft. lbs. (68 N m)

• On TB, TE & TJ Series Torqmotors, pressure port with “A” cast under it on housing (18) is for clockwisecoupling shaft rotation as viewed from the output end of coupling shaft. Pressure port with “B” cast underit is for counter clockwise coupling shaft rotation.

• On TF, TG, & TH Series Torqmotors, pressure port with “B” cast under it on housing (18) is for clockwisecoupling shaft rotation as viewed from the output end of coupling shaft. Pressure port with “A” case underit is for counter clockwise coupling shaft rotation.

• Use test stand if available, to check operation of the Torqmotor™.

Hydraulic Fluid

Keep the hydraulic system filled with one of the following:

• 10W40 SE or SF manufacturers suggested oil.

• Hydraulic fluid as recommended by equipment manufacturer, but the viscosity should not drop below 50 SSU orcontain less than .125% zinc anti-wear additives.

CAUTION: Do not mix oil types. Any mixture, or an unapproved oil, could deteriorate the seals. Maintainthe proper fluid level in the reservoir. When changing fluid, completely drain old oil from the system. Itis suggested also that you flush the system with clean oil.

Filtration

Recommended filtration 20-50 micron.

Oil Temperature

Maximum operating temperature 200°F (93.3° C).

Final Checks



50

Tips for Maintaining the Torqmotor™ Hydraulic System

• Adjust fluid level in reservoir as necessary.

• Encourage all operators to report any malfunction or accident that may have damaged the hydraulic systemor component.

• Do not attempt to weld any broken Torqmotor™ component. Replace the component with original equipmentonly.

• Do not cold straighten, hot straighten, or bend any Torqmotor™ part.

• Prevent dirt or other foreign matter from entering the hydraulic system. Clean the area around and the filler capsbefore checking oil level.

• Investigate and correct any external leak in the hydraulic system, no matter how minor the leak.

• Comply with manufacturer’s specifications for cleaning or replacing the filter.

CAUTION: Do not weld, braze, solder or any way alter any Torqmotor™ component.

CAUTION: Maximum operating pressure must not exceed recommended Torqmotor™ pressure capacity.

CAUTION: Always carefully inspect any system component that may have been struck or damagedduring operation or in an accident. Replace any component that is damaged or that is questionable.

CAUTION: Do not force any coupling onto the Torqmotor™ coupling shaft as this could damage the unitinternally.

Parker extends close technical cooperation and assistance. If problems occur which you cannot solve, pleasecontact your local Parker approved Distributor or Parker Technical Support. Our phone number and fax numberand address are on the back cover of this manual.

Tips



51

Notes



52

Notes



53

Notes



54

Notes



55

The items described in this document and other documents or descriptions provided by Parker Hannifin Corporation, its subsidiaries and its authorizeddistributors are hereby offered for sale at prices to be established by Parker Hannifin Corporation, its subsidiaries and its authorized distributors. Thisoffer and its acceptance by any customer ("Buyer") shall be governed by all of the following Terms and Conditions. Buyer’s order for any such items,when communicated to Parker Hannifin Corporation, its subsidiary or an authorized distributor ("Seller") verbally or in writing, shall constitute acceptanceof this offer.

right to alter, discard or otherwise dispose of any special tooling or otherproperty in its sole discretion at any time.8. Buyer’s Property: Any designs, tools, patterns, materials, drawings,confidential information or equipment furnished by Buyer or any otheritems which become Buyer’s property, may be considered obsolete andmay be destroyed by Seller after two (2) consecutive years have elapsedwithout Buyer placing an order for the items which are manufactured usingsuch property, Seller shall not be responsible for any loss or damage tosuch property while it is in Seller’s possession or control.9. Taxes: Unless otherwise indicated on the face hereof, all prices andcharges are exclusive of excise, sales, use, property, occupational or liketaxes which may be imposed by any taxing authority upon the manufac-ture, sale or delivery of the items sold hereunder. If any such taxes mustbe paid by Seller or if Seller is liable for the collection of such tax, the amountthereof shall be in addition to the amounts for the items sold. Buyer agreesto pay all such taxes or to reimburse Seller therefore upon receipt of itsinvoice. If Buyer claims exemption from any sales, use or other tax imposedby any taxing authority, Buyer shall save Seller harmless from and againstany such tax, together with any interest or penalties thereon which maybe assessed if the items are held to be taxable.10. Indemnity For Infringement of Intellectual Property Rights: Sellershall have no liability for infringement of any patents, trademarks,copyrights, trade dress, trade secrets or similar rights except as providedin this Part 10. Seller will defend and indemnify Buyer against allegationsof infringement of U.S. Patents, U.S. Trademarks, copyrights, trade dressand trade secrets (hereinafter ‘Intellectual Property Rights’). Seller willdefend at its expense and will pay the cost of any settlement or damagesawarded in an action brought against Buyer based on an allegation thatan item sold pursuant to this contract infringes the Intellectual PropertyRights of a third party. Seller’s obligation to defend and indemnify Buyeris contingent on Buyer notifying Seller within ten (10) days after Buyerbecomes aware of such allegations of infringement, and Seller having solecontrol over the defense of any allegations or actions including allnegotiations for settlement or compromise. If an item sold hereunder issubject to a claim that it infringes the Intellectual Property Rights of a thirdparty, Seller may, at its sole expense and option, procure for Buyer theright to continue using said item, replace or modify said item so as to makeit noninfringing, or offer to accept return of said item and return thepurchase price less a reasonable allowance for depreciation. Notwith-standing the foregoing, Seller shall have no liability for claims of infringe-ment based on information provided by Buyer, or directed to itemsdelivered hereunder for which the designs are specified in whole or partby Buyer, or infringements resulting from the modification, combination oruse in a system of any item sold hereunder. The foregoing provisions ofthis Part 10 shall constitute Seller’s sole and exclusive liability and Buyer’ssole and exclusive remedy for infringement of Intellectual Property Rights.If a claim is based on information provided by Buyer or if the design foran item delivered hereunder is specified in whole or in part by Buyer, Buyershall defend and indemnify Seller for all costs, expenses or judgmentsresulting from any claim that such item infringes any patent, trademark,copyright, trade dress, trade secret or any similar right.11. Force Majeure: Seller does not assume the risk of and shall not beliable for delay or failure to perform any of Seller’s obligations by reasonof circumstances beyond the reasonable control of Seller (hereinafter‘Events of Force Majeure’). Events of Force Majeure shall include withoutlimitation, accidents, acts of God, strikes or labor disputes, acts, laws, rulesor regulations of any government or government agency, fires, floods,delays or failures in delivery of carriers or suppliers, shortages of materialsand any other cause beyond Seller’s control.12. Entire Agreement/Governing Law: The terms and conditions setforth herein, together with any amendments, modifications and anydifferent terms or conditions expressly accepted by Seller in writing, shallconstitute the entire Agreement concerning the items sold, and there areno oral or other representations or agreements which pertain thereto. ThisAgreement shall be governed in all respects by the law of the State of Ohio.No actions arising out of the sale of the items sold hereunder or thisAgreement may be brought by either party more than two (2) years afterthe cause of action accrues.

9/91-P

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Offer of Sale

Parker Hannifin Corporation2745 Snapps Ferry RoadGreeneville, TN 37745 USATel: (423) 639-8151FAX: (423) 787-2418www.parker.com/pumpmotor

Installation and Maintenance InstructionsModel: Short FBH-W Series

Spring Applied, Hydraulically-Released Multiple Plate Brake for Wet Operation.

Installation.

Position 1-off gasket (5) over male pilot on brake housing(4).Locate brake shaft (1) and secure brake in position using2-off ½” UNC mounting bolts in the through mounting(fixing) holes provided.Connect hydraulic pressure supply to brake pressure inletport. Ensure that the hydraulic pressure is set to therequired level up to a maximum of 3000 psi (200 bar) andcheck that the brake disengages and re-engages correctly.

Maintenance.

The brake is required to be kept in good working order andmust be included in the planned maintenance programmefor the equipment to which the brake is installed.This must include torque testing together with inspectionand replacement of the working parts such as frictionplates (3 & 6) and, springs (22 & 23). The frequency ofinspection depends on the duty demanded of the brake.

Dismantling (and dis-assembly).

To remove brake from its installed position, reverseprocedure previously described in the Installationinstructions.Place the complete brake assembly on a clean, dryworkbench.

Remove external gaskets (5) as necessary.

REFER TO DIAGRAMS FOR THE FOLLOWING.

1) Supporting brake on face ‘A’, remove the six sockethead cap screws (SHCS) and washers (items 13 & 14)in equal increments to ensure the spring pressure withinthe brake is reduced gradually and evenly.Alternatively, if a press is available, the cylinder housing(8) can be restrained on face ‘B’ while removing the sixSHCS and washers (13 & 14).The brake assembly can now be fully dismantled andthe parts examined.

2) Remove cylinder housing (8) and piston (9) sub-assembly and dismantle if required, removing ‘O’ ringseals (15 & 17) and backing rings (16 & 18) asnecessary.

3) Remove gasket (7) from housing (2).

4) Remove friction plates (3 & 6) and pressure plate (4).

5) Remove 2-off dowel pins (19).

6) Remove springs (22 & 23).Note: See chart on page 4 for spring arrangement andquantities for the particular brake model used.

7) Should it be necessary to replace ball bearing (10) orshaft seal (12), reverse remainder of brake sub-assembly, supporting on face ‘C’ of housing (2).

8) Remove internal retaining ring (11).

9) Using arbor press or similar to break ‘Loctite’ seal,remove brake shaft (1) from housing (2) and lay aside.

10) Reverse housing (2) and press out ball bearing (10).Shaft seal (12) can also be removed if necessary.

Examination.

All components can now be examined and inspected,paying particular attention to the following.

1) Inspect friction plates (3 & 6) and friction surface onpressure plate (4) for wear or damage.

2) Examine friction plates (3) and brake shaft (1) for wearor damage to the splines.

3) Examine input and output splines of brake shaft (1) forwear or damage.

4) Examine compression springs (22 & 23) for damage orfatigue.

5) Check ball bearing (10) for axial float or wear.

6) Examine ‘O’ ring seals (15 & 17) and backing rings (16& 18) for damage.

OBTAIN REPLACEMENT PARTS AS REQUIRED.

Assembly.

Clean all parts thoroughly.Reverse procedure previously outlined in Dismantlinginstructions taking particular care with.a) Assembly of shaft seal (12).b) Assembly of bearing (10).c) Quantity and orientation of springs (22 & 23).

Note: See chart on back page for spring quantities andarrangement for the particular brake model used.

d) Assembly sequence of friction plates (3 & 6).-Seediagram.

1) Lightly lubricate rotary shaft seal (12) and assemble tohousing (2) taking care not to damage seal lip.

2) Apply ring of Loctite 641 or equivalent adhesive to fullcircumference of housing (2) bearing recess adjacent toshoulder.Apply complete coverage of Loctite 641 to outsidediameter of bearing (10) and assemble fully in housing(2), retaining with internal retaining ring (11). Removeexcess adhesive with a clean cloth.Secure and seal bearing inner ring to shaft (1) usingLoctite 641 applied to bearing inner diameter. Removeany excess adhesive with a clean cloth.

3) Assemble correct quantity of springs (22 & 23) inorientation required.

Installation and Maintenance InstructionsModel: Short FBH-W Series

Spring Applied, Hydraulically-Released Multiple Plate Brake for Wet Operation.

4) Lubricate ‘O’ ring seals (15 & 17) with Molykote 55M(or equivalent) silicon grease and assemble togetherwith backing rings (16 & 18) to piston (9). To ensurecorrect brake operation, it is important that the backingrings are assembled opposite to the pressurised sideof piston (9).

5) Correctly orientate piston (9) aligning spaces with thetwo dowel pin holes and, assemble into cylinderhousing (8) taking care not to damage seals andcarefully lay aside.

6) Locate 2-off pins (19) in housing (2) followed bypressure plate (4) and friction plates i.e. an inner (3)followed by an outer (6) in correct sequence.

7) Position gasket (7) in correct orientation.

8) Align two holes in cylinder with dowel pins (19) andassemble piston & cylinder sub-assembly to remainderof brake securing with 6-off SHCS and washers (13 &14). Torque tighten to 55 lbF.ft (75 Nm).Note: The use of a suitable press (hydraulic or arbor)pressing down on cylinder end face ‘B’ will easeassembly of the SHCS (13).

Note: If new friction plates have been assembled,it is recommended that the friction faces are“bedded in” to help ensure stable torqueperformance.

INTRODUCTION

This manual is a step-by-step guide to assembly and dis-assembly of torque-hub units. It is designed for the customer orshop mechanic who is repairing a particular model of torque-hubfinal drive. Users of this manual should note that each partmentioned is followed by an indentification number enclosed inparentheses. These part numbers may be referred to in the PartsList section of this manual and on the cross-sectional view of thisunit. A print of each tool discussed in this manual is shown in theTooling section. Users should familiarize themselves with theprocedures for roll and leak testing and bolt tightening andtorquing found on the following two pages before getting started.

This manual includes the following sections.

1. Roll and Leak Testing Procedures

2. Bolt Tightening and Torquing Procedures

3. Disassembly Procedures

4. Sub-Assembly Procedures

5. Main Assembly Procedure

6. Drawings of all Essential Tools

7. Parts List

8. Cross-Sectional View of the Unit

SAFETY

Standard safety practices should be followed during thedisassembly and assembly procedures described. Safety glasses andsafety shoes should be worn. Heavy, heat resistant gloves should beused when heated components are handled. Be especially alert whenyou see the word CAUTION. This indicates that a particularoperation could cause personal injury if not performed properly orif certain safety procedures are not followed.

I

ROLL and LEAK TESTING

Torque-hub units should always be roll and leak tested beforedisassembly and after assembly to make sure that the unit’s gearsand sealants are working properly. The following information brieflyoutlines what to look for when performing these tests.

THE ROLL TEST

The purpose of a roll test is to determine if theunit’s gears are rotating freely and properly. You shouldbe able to rotate the gears in your unit by applying aconstant force to the roll checker. If you feel more dragin the gears only at certain points, then the gears are notrolling freely and should be examined for proper install-ation or defects. Some gear packages roll with more diffi-culty than others. Do not be concerned if the gears inyour unit seem to roll hard as long as they roll withconsistency.

THE LEAK TEST

The purpose of a leak test is to make sure that theunit is air tight. You can tell if your unit has a leak ifthe pressure gauge reading on your air checker starts tofall once the unit has been pressurized. Leaks will mostlikely occur at the main seal or wherever “O” rings orgaskits are located. The exact location of a leak canusually be detected by brushing a soap and watersolution around the main seal and where “O” rings orgaskits meet the exterior of the unit then checking forair bubbles. If a leak is detected in a seal, “O” ring, orgaskit, the part must be replaced.

II

TIGHTENING and TORQUING BOLTS

If an air impact wrench is used to tighten bolts,extreme care should be taken to insure that bolts are nottightened beyond their indicated torque specification.Never use an impact wrench to tighten shoulder bolts, allshoulder bolts should be tightened by hand.

The following steps describe the proper procedure fortightening and torquing bolts or socket head cap screwsin a bolt circle.

1. Tighten (but do not torque) bolt“A” until snug.

2. Go to the opposite side of the boltcircle and tighten bolt “B” untilequally snug.

3. Continue around the bolt circleand tighten the remaining bolts.

4. Now use a torque wrench to applythe specified torque to bolt “A”

5. Continue around the bolt circleand apply an equal torque to theremaining bolts.

III

MAIN DISASSEMBLY

1. Remove pipe plug (15) from cover(6)and drain the oil from the unit.

2. Roll test the unit in bothclockwise and counterclockwisedirections. Perform the same numberof turns in each direction as theratio of the unit. The ratio number isthe same as the last two digits in themodel number found on the ID tag ofthe unit.

3. Leak test the unit at a pressure of5 psi for 2-3 minutes.

4. Remove all 24 grade 8 bolts(16)from cover(6).

1

5. Lift cover(6) off of hub(1G) andremove “O” ring(5) from the counter-bore in the cover. Discard the “O”ring.

6. Remove small thrustwasher(7) fromthe counterbore in the center hole incover(6).

7. Remove large thrust washer(14),thrust bearing(13), and large thrustwasher(12) from the raised insidecircular edge of cover(6).

8. Remove input gear(8) from meshwith the planet gears in first stagecarrier assembly(3).

9. Lift out first stage carrierassembly(3).

2

10. Remove small thrust washer(9)from the top of second stage sungear(11).

11. Remove thrust bearing carrier(10),large thrust washer(14), thrust bear-ing(13), and large thrust washer(12)from the counterbore of second stagecarrier assembly(2).

12. Remove second stage sun gear(11)from mesh with second stage carrierassembly(2).

13. Lift out ring gear(4).

14. Remove “O” ring(5) from thecounterbore in hub(1G) and discard.

3

15. Lift out second stage carrierassembly(2) from mesh with outputshaft(1A).

16. Using retaining ring pliers,remove retaining ring(1L) from groovearound the outside of output shaft(1A).

CAUTION: Safety glasses should beworn during this procedure.

17. With a screwdriver or chisel andhammer, straighten out the tang onlockwasher(1J) which has been bentinto the notch on locknut(1K).

18. Using an AN-18 locknut wrench(tool no T-156766), loosen locknuts(1K). Remove the locknut from outputshaft(lA) and discard.

NOTE: The output shaft must be heldsecurely enough to resist turningwhen the locknut is loosened.

19. Remove lockwasher(1J) and tangedwasher(1H) from output shaft(1A).Discard the lockwasher.

4

5

20. Raise hub(1G) above your worksurface and support it fromunderneath in a manner that willallow output shaft(1A) to fall throughthe bottom. Press the output shaftout of the hub. The output shaft willcome out with bearing cone (1D)attached and seal(1B). Discard theseal.

21. Remove bearing cone (1D) fromoutput shaft(lA).

22. Lift bearing cone(1F) out ofhub(1G).

23. Using a soft punch and hammer,remove bearing cups (1E) and (1C)from hub(1G). Be very careful not tostrike the counterbores of the hubwhere these cups are located whenusing the punch.

24. Remove all four pipe plugs (1M),(1N), and (1P) from hub(1G).

25. At this point the main disassemblyis complete.

FIRST STAGE CARRIER DISASSEMBLY

1. Locate dowel pin(3D) which holdsplanes shaft(3E) in carrier housing(3A).

2. Drive the dowel pin(3D) down intoplanes shaft(3E) until it bottomsagainst the carrier housing. If thedowel pin is not completely driveninto the planet shaft, damage to thecarrier could occur when the shaft isremoved.

3. Remove planet shaft(3E) fromcarrier housing(3A). The four thrustwashers(3B) and planet gear(3F) willslide off.

4. Using an alignment punch andhammer, drive dowel pin(3D) outthrough the end of the dowel pinhole in planet shaft(3E) that itoriginally went into.

6

5. Remove needle rollers(3C) frominside planet gear(3F).

6. Repeat steps 1-5 to remove the two remaining planet gears.

7. At this point the first stage carrier disassembly is complete.

7

SECOND STAGE CARRIER DISASSEMBLY

1. Locate dowel pin(2G) which holdsplanet shaft(2E) in carrier housing(2A).

2. Drive dowel pin(2G) down intoplanets shaft(2E) until it bottomsagainst the carrier housing. If thedowel pin is not completely driveninto the planet shaft, damage to thecarrier could occur when the shaft isremoved.

3. Remove planet shaft(2E) fromcarrier housing(2A). The four thrustwashers(2B) and planet gear(2F) willslide off.

4. Using an alignment punch andhammer, drive dowel pin(2G) outthrough the end of the dowel pinhole in planet shaft(2E) that itoriginally went into.

8

9

5. Remove needle rollers(2C) andspacer(2D) from inside planesgear(2f)

6. Repeat steps 1-5 to remove the two remaining planets gears.

7. At this point the second stage carrier disassembly is complete.

FIRST STAGE CARRIER SUB-ASSEMBLY

1. Apply grease to the inside of onefirst stage carrier planes gear(3F).

2. Line the inside of planet gear(3F) with 19 needle rollers(3C).

3.Stand first stage carrier housing(3A)in an upright position.

4. Insert a planet shaft(3E) intoone of the planet shaft roles whichhas a dowel pin hole on carrierhousing(3A). The end of the planetshaft that does not have the dowelpin hole should be inserted into thecarrier housing first.

10

NOTE: One end of the dowel pin hole on the planet shaft has achamfer or gradual slope. This end should be up to allow easyalignment.

11

5. Place two thrust washers(3B) ontothe end of planet shaft(3E) whichhas been inserted through the planetshaft hole in carrier housing(3A).

NOTE: Grease or petroleum jelly maybe used to hold the washers togetherand in place on the planet shaft.

6. Following the thrust washersplace planet gear (3F), with needlerollers, onto planet shaft (3E).

7. Following the planet gear, placetwo more thrust washers(3B) ontoplanet shaft(3E).


8. Now insert planet shaft(3E)through the opposite planet shafthole on carrier housing(3A).

9. Using an alignment puch orsimilar tool, align the dowel pinholes on carrier housing(3A) andplanet shaft (3E).

10. If you examine a dowel pin (3D)carefully, you will notice that oneend is smaller than the other. Drivethis end of the dowel pin (3D) downinto the aligned dowel pin holes. Itshould be driven to just below (1/10in.) the surface of the carrierhousing.

ll. Repeat the procedure in steps 1-10 for installation of thetwo remaining first stage planes gears(3F).

l2. At this point the first stage carrier sub-assembly is com-plete.

12

SECOND STAGE CARRIER SUB-ASSEMBLY

1. Apply grease to the inside of onesecond stage planet gear(2F).

2. Line one half of planet gear(2F)with 18 needle rollers(2C).

3. Place one spacer(2D) insideplanet gear(2F) so that it rests ontop of the needle rollers (2C).

4. Line the remaining half of planetgear(2F) with 18 needle rollers(2C).

13

5. Stand second stage carrier housing(2A) in an upright position.

6. Insert planet shaft(2E) into aplanet shaft hole that does not havea dowel pin hole on carrier housing(2A). The end of the planet shaftwith the dowel pin hole should beinserted into the carrier housingfirst.

7. Place two thrust washers(2B) ontothe end of the planet shaft whichhas been inserted through the planetshaft hole.


8. Following the thrust washers,place planet gear(2F), with needlerollers, onto planes shaft(2E).

NOTE: One end of the dowel pin hole on the planet shaft has achamfer or gradual slope. This end should be up to allow easyalignment.

14

15

9. Following the planet gear, placetwo more thrust washers(2b) untoplanet shaft(2E).


10. Now insert planet shaft(2E)through the opposite planet shafthole on carrier housing(2A).

11. Using an alignment punch orsimilar tool, align the dowel pinholes on the carrier housing andplanet shaft.

12. If you examine a dowel pin(2G)carefully, you will notice that oneend is smaller than the other. Drivethis end of dowel pin(2G) down intothe aligned dowel pin holes. Itshould be driven to just below (1/10in.) the surface of the carrierhousing.

13. Repeat the procedure in steps 1-12 for installation of thetwo remaining second stage planet gears(2F).

14. At this point the second stage carrier sub-assembly iscomplete.

1. Apply a light coat of “Never-Seize” to the four hub pipe plugs(1M), (1N), and (1P).

Note: Pipe plug(1P) is a magneticplug.

2. With hub(lG) standing on itslarge diameter end, tighten pipeplugs(1M) into the two pipe plugholes nearest the small diameter endof hub(1g).

NOTE: Notice that pipe plugs(lM) aremuch smaller than pipe plugs (1N)and (1P).

3. Turn hub(1G) over so that itrests on its small diameter end andthe two pipe plug holes nearest thehub’s large diameter and are facingyou. Tighten magnetic pipe plug(1P)into the right-hand pipe plug hole.

4. Mark the location of magneticpipe plug(1P) so that it may bealigned with the pipe plug hole incover(6) in a later step.

HUB-SHAFT SUB-ASSEMBLY

16

5. Install pipe plug(1N) into the left-hand pipe plug holenearest the large diameter end of hub (1G).

6. With hub(1G) still standing onits large diameter end, press bear-ing cup(1C) into the small diameterend of hub(1G) usina a bearing cuppressing fixture (tool no.T- 156792).

NOTE: Make sure that the cup sitssquare with the counterbore of thehub before pressing.

7. Turn hub(1G) over so that itrests on its small diameter end.Press bearing cup(1E) down intohub(lG) using a bearing cup pressingfixture (tool no. T-130717).

NOTE: Make sure that the cup sitssquare with the counterbore of thehub before pressing.

8. Spray the inside of bearingcone(1D) with oil.

9. Press bearing cone(1D) onto out-put shaft(1A) using a bearing conepressing fixture (tool no.T-158049).

17

18

10. With small diameter end down,lower hub(1G) onto output shaft(1A).

11. Spray the inside of bearingcone(1F) with oil.

12. Press bearing cone(1F) ontooutput shaft(1A) using a bearingcone pressing fixture (tool no. T-146588). Reduce the pressure appliedto the bearing cone and press thecone again. This time rotate thehub in both clockwise and counter-clockwise directions while pressing.Stop pressing when the hub starts toresist the rotation.

a) Tighten a bolt into one of thebolt holes on the hub. The bolt usedshould be one that fits the hole.

13. Now measure the initial rolling torque of hub(1G). To dothis, follow steps a-d.

b) Place a torque wrench on the bolt so that the arm of thewrench lines up on a tangent to the circumference of the hub asshown in figure 1.

19

c) Keeping the wrench in thisposition at all times, use the armof the wrench to guide the hubaround in one rotation.

14. Place tanged Fwasher(1H) ontooutput shaft(1A).

d) Read the gauge on the torque wrench. The initial rollingtorque should be 25-30 in.-lbs. Measure the rolling torqueseveral times to insure an accurate reading.

NOTE: If the initial rolling torque is less than 25 in.-lbs.,apply more pressure to bearing cone(1F). If the initial rollingtorque is higher than 30 in.-lbs., strike the top of outputshaft(1A) with a soft face hammer to release the load on theshaft, then repeat steps 13b - 13d.

Rolling Torque Procedure

THE CORRECT READING CAN ONLY BE MADE IF THETORQUE WRENCH IS PULLED SLOWLY (APPROX. 3.5 R.P.M.)AND SMOOTHLY TOWARDS YOU.

Figure 1.

20

15. Place lockwasher(1J) onto outputshaft(1A).

NOTE: Notice that lockwasher(1J) hastangs and tanged washer(1H) doesnot.

16. Spray the inside of locknut(1K)and the exposed sides of outputshaft(1A) with Locquic Primer T.Allow two minutes drying time.

17. Apply Loctite 277 Adhesive/Sealant to the second screwthreadfrom the bottom of locknut(1K).

NOTE: The bottom of locknut(1K) hasa chamfered or inward sloping edge.

18. Place locknut(1K) onto outputshaft(1A) and screw into place.

NOTE: Loctite 277 is an anaerobic adhesive. Once it has beenremoved from air, it sets. Therefore, once the locknut has beenplaced on the output shaft, it must be torqued immediately or theadhesive will make it difficult to turn.

21

22

19. Using an AN-18 locknut wrench(tool no. T-156766) and a torquewrench, apply 225 ft.-lbs. of torqueto locknut(1K).

20. Measure the final rolling torqueof hub(1G) using the same mannerdescribed in steps 13a - 13d. Thefinal rolling torque should measure35-60 in.-lbs.

NOTE: Remove the bolt from the hub.

21. Bend the aligned tang onlockwasher(1J) up into the notch onlocknut(1K).

22. Using a center punch and hammer,stake locknut(1K) in four equallyspaced positions around the cir-cumference of the locknut and at adistance of 1/8 in. from the insideedge of the locknut.

23. At this point the hub-shaft sub-assembly is complete.

NOTE: One tang on lockwasher(1J) must line up directly with onenotch on locknut(1K). If one tang does not line up with alocknut notch, apply sufficient increased torque to the locknutuntil it does. Never loosen the locknut.

1. Turn hub(1G) over so that itrests on its large diameter end.Spray oil on all exposed surfacesinside the hub while turning outputshaft(1A).

2. Spray the inside of seal(1B) withoil.

NOTE: The open face of the seal mayhave a waved surface. This is anintentional design used to keep dirtout.

3. Press seal(1B) into the smalldiameter end of hub (1G) using a sealpressing fixture (tool no.T-156799).

4. Turn hub(1G) over once again sothat it rests on its small diameterend. Using retaining ring pliers,insert retaining ring(1L) into thegroove on output shaft(1A).

CAUTION: Saftey glasses should beworn during this procedure.

MAIN ASSEMBLY

23

24

5. Place second stage carrier assem-bly(2), with spline connections down,into hub(1G) so that the carrier’sspline connections mesh with thespline connections on output shaft(1A).

6. Spray oil on all exposed surfacesinside hub(1G).

7. Grease “O” ring(5).

8. Place “O” ring(5) into thecounterbore of hub(1G). Make surethat the counterbore is oil freebefore installing “O” ring.

CAUTION: Beware of sharp edges andburrs in the counterbore while in-stalling the “O” ring.

NOTE: “O” rings may be stretched to fit the counterbore. If an“O” ring has been stretched too much, simply squeeze the “O” ringtogether bit by bit as you place it around the counterbore. Itcan be made to fit exactly.

25

9. Spary oil on the inside of ringgear(4).

10. Place ring gear(4) with smalldiameter end down, into hub(lG) sothat it fits over second stagecarrier assembly(2).

11. Place second stage sun gear(11),with large diameter end down, intomesh with the planet gears of thesecond stage carrier assembly(2).

l2. Place large thrust washer(14),thrust bearing(13), and large thrustwasher(12) in that order into thecounterbore of second stage carrierassembly(2).

NOTE: Notice that thrust washer(14)is much thicker than thrustwasher(12).

13. Place thrust bearing carrier(10), with small diameter end down,into the counterbore of second stagecarrier assembly(2). It should fitover the thrust bearing set(12, 13,14) described in step 12.

26

14. Place first stage carrierassembly(3), with spline connectionsdown, into mesh with the secondstage sun gear(ll) and the ringgear(4).

15. Place small thrust washer(9) ontop of second stage sun gear(ll).

16. Place input gear(8), with smalldiameter end down, into mesh withthe planet gears of first stagecarrier assembly(3). The input gearshould be centered on the smallthrust washer(9).

18. Grease one side of large thrustwasher(12), thrust bearing(13), andlarge thrust washer(14) and placethem greased side down in that orderover the raised inside circular edgeof cover(6).

NOTE: Notice that thrust washer(14)is much thicker that thrust washer(12).

17. Set cover(6) down on its small diameter end.

19. Grease small thrust washer(7)and place it in the counterbore ofthe center hole in cover(6).

20. Grease “O” ring(5) and place itaround the counterbore in cover(6).

CAUTION: Beware of sharp edges andstalling the “O” ring.

21. Place cover(6), with largediameter end down, on top of ringgear(4) so that the cover ’s pipeplug hole aligns with the magneticpipe plug hole in hub(lG) accordingto figure 2.

NOTE: “O” rings may be stretched to fit the counterbore. If an“O” ring has been stretched too much, simply squeeze the “O” ringtogether bit by bit as you place it around the counterbore. Itcan be made to fit exactly.

27

28

Pipe Plug Timing

This figure shows the most commonpipe plug timing for this series.Pipe plug timings may vary amongunits with different model numbers.Refer to an original assembly printfor your particular unit to deter-mine its correct pipe plug timing.

22. Place the 24 grade 8 bolts(16)into cover(6) and tighten.

23. Using a torque wrench, apply 35-45 ft.-lbs of torque to each grade8 bolt (16).

Figure 2.

29

24. Apply a light coat of “Never-Seize” to pipe plug(15).

25. Tighthen pipe plug(15) into thepipe plug hole in cover(6).

26. Roll test the unit in bothclockwise and counterclockwisedirections. Perform the same numberof turns in each direction as theratio of the unit. The ratio numberis the same as the last two digitsin the model number found on the IDtag of the unit.

27. Leak test the unit at a pressureof 5 psi for 2-3 minutes.

28. At this point the main assemblycomplete.

TOOLING

The following specialized tools are used in the assembly ofthis unit. The tool diagrams included in this manual are intendedfor the customer who may wish to have a tool made. All tools mustbe made from mild steel. All dimensions are given in inches.

OPTIONAL: In order to improve tool life, tools may be carborizedand hardened. If this is done, however, the tools must be groundon all surfaces labeled with a “G” on the tool diagram.

1. TOOL NO. T-130717BEARING CUP PRESSING FIXTURE for CUP(1E)

2. TOOL NO. T-156792BEARING CUP PRESSING FIXTURE for CUP(1C)

3. TOOL NO. T-158049BEARING CONE PRESSING FIXTURE for CONE(1D)

4. TOOL NO. T-146588BEARING CONE PRESSING FIXTURE for CONE(1F)

5. TOOL NO. T-156766AN-18 LOCKNUT WRENCH

6. TOOL NO. T-156799SEAL PRESSING FIXTURE

30

SCALE: 3/4 ONE PIECET-130717

BEARING CUP PRESSING FIXTUREfor CUP(1E)

31

T-156792SCALE: 3/4

BEARING CUP PRESSING FIXTUREfor CUP(1C)

32

T-158049SCALE: 3/4 ONE PIECE

BEARING CONE PRESSING FIXTUREfor CONE(1D)

33

T-146588SCALE: full ONE PIECE

BEARING CONE PRESSING FIXTUREfor CONE(1F)

34

T-156766SCALE: 2/3 ONE PIECE

AN-18 LOCKNUT WRENCHUSE 3/4 in. DRIVE SOCKET

35

T-156799 SCALE: 2/3

SEAL PRESSING FIXTURE

36

PARTS LIST

ITEM

hub-spindle sub-assemblyoutput shaftsealbearing cupbearing conebearing cupbearing conehubtanged washerlockwasherlocknutretaining ringpipe plugpipe plugmagnetic pipe plug

second stage carrier sub-assemblysecond stage carrierthrust washerneedle rollerspacerplanet shaftplanet geardowel pin

first stage carrier sub-assembly1 first stage carrierthrust washerneedle rollerdowel pinplanet shaftplanet gear

ring gear“O” ringcoverthrust washer

input gearthrust washer

QUANTITY DESCRIPTION

1A1B1C1D1E1F1G1H1J1K1L1M1N1P

2A2B2C2D2E2F2G

3A3B3C3D3E3F

37

11111111111211

1121083333

11257333

1

2

3

456789

1

1

1

121111

ITEM

thrust bearing carriersecond stage sun gearthrust washerthrust bearingthrust washerpipe plugboltdrive screwID plate

QUANTITY DESCRIPTION

101112131415161718

1122212441

38

CROSS-SECTIONAL VIEW of S6A

39

13 4 CAPSCREW GR 8

1

2

3

3

4

5

6

7

8

9

10

9

6

5

4

11

12

13

13

12

Note: Before disassembling ensure that the unit, bench and tools are thoroughly clean.

Disassembly Instructions:1. Where applicable, remove the drive coupling from the drive shaft using a suitable puller. The coupling

must not be levered or hammered as this may cause internal pump damage.2. If the pump has a keyed shaft, remove the key from the shaft. Lightly stone any burrs that may be on

the shaft to prevent any damage to the seal during disassembly.3. Clamp the pump in a vise using the mounting flange (2), with the drive shaft pointing down. Do not

clamp on the machined pilot ring.4. Scribe a line across the shaft end cover (2), gear housing (10) and port end cover (11). This will

ensure proper alignment during reassembly.5. Remove all the mounting bolts (13) and washers (12) from the assembly.6. Remove the rear port end cover (11).7. Lift the gear housing (10) off of the shaft end cover (2), tapping the housing with a soft mallet, if neces-

sary.8. Remove the rear bushing block (6) noting the orientation of the channel seal (5).9. Carefully remove the gears by pushing up on the drive shaft (7). Remove the front bushing block (6)

noting its orientation.

Change of Rotation Instructions:These instructions are intended for use in changing the rotation of a single section PGP500 series gear pump.Reassembly Instructions:

1. Rotate front bushing block (6) 180° from original position and place on shaft end cover (2). Make surethe backup seals (4) and channel seals (5) are seated properly.

Instructions:Change of Rotation

and Seal Replacement(PGP500 Series)

Parker Hannifin CorporationGear Pump Division1775 Logan AvenueYoungstown, Ohio 44501Tel: (330) 746-8011 Fax: (330) 746-1148http://www.parker.com/gearpump

Item Quantity Description13 4 Capscrew12 4 Washer11 1 Housing, Pec10 1 Housing, Gear9 2 Sea, O-R8 1 Gear, driven7 1 Gear, drive6 2 Thrblk5 2 Channel Seal4 2 Seal, bk-up3 2 Pin, dowel2 1 Housing, sec1 1 Lip seal

2. Seat O-rings (9) in the machined groove and rotate housing (10) 180° around the shaft axis andplace onto shaft end cover (2). Readjust location of dowel pins (3) if pulled out at disassembly.Note from Disassembly Step 4 that the line on the housing (10) and cover (2) should now be onopposite sides.

3. Slide the drive shaft gear (7) through the gear housing, bushing, and shaft seal. Be careful not todamage the shaft seal. Slide the driven gear (8) through the gear housing and into the bushing.

4. Rotate rear bushing block (6) 180° from original position and place on gears. Make sure thebackup seals (4) and channel seals (5) are seated properly.

5. From its original position, rotate the port end cover (11) 180° around the shaft axis and position itover the gear housing.

6. Replace the washers and bolts into the unit. Torque bolts in a diagonal pattern. Dry assemblytorques are given in Table 1. Do not over torque.

7. Rotate drive shaft with a small wrench to check for any binding.

Table 1: PGP/PGM500 series assembly torques

SERIES PGP/PGM505 PGP/PGM511 PGP/PGM517

ASSEMBLY TORQUE 300 in-lbs(25 ft-lbs) 420 in-lbs (35 ft-lbs) 1000 in-lbs (83 ft-lbs)

Seal Replacement Instructions:

These instructions are intended for use in changing the seals of a single PGP/PGM500 series gear pumpor motor. Note the shape and orientation of all seals before and during removal.

1. If shaft end cover has a snap ring and outboard bearing, carefully remove. Insert a small diam-eter punch or screwdriver from inside the cover into the shaft seal opening. Gently tap to driveout the shaft seal.

2. Press the replacement shaft seal (1) squarely into the seal recess in the shaft end cover until itbottoms out. Lip seal garter spring faces in toward unit. Reinstall snap ring and bearing if appli-cable. Remount cover (2) in the vise.

3. Remove old plastic and rubber seals from the thrust blocks (6) and replace with new seals (4 &5). Note seal orientation. Grease will help hold the seals in place.

4. Remove section seals (9) from housing (10) and replace with new o-rings. Light grease will helphold the seals in place.

5. Replace the front thrust block (6) on the shaft end cover (2) with seals facing down. For pumps,orient so middle of seal points to low pressure (inlet) side.

6. Position housing (10) on the cover (2) making sure the lines from Disassembly Step 4 match up(unless changing rotation). Tap in place with a soft mallet.

7. Replace the drive gear (7) and driven gear (8). If included in the seal kit, put the protective sleeveover the drive shaft before pushing through the shaft seal.

8. Replace the rear thrust block (6), seals facing up, with the middle of the seal pointing to the lowpressure side.

9. Reinstall the port end cover (11) aligning the markings with the housing and shaft end cover.10. Replace the four bolts and washers. Torque in a diagonal pattern according to the values

in Table 1.

BULLETIN NO.GZ-MS-A066-3000E MAG-170VP-3000E-1 SERVICE MANUAL KAYABA INDUSTRY CO. LTD / KYB AMERICA LLC

06/25/1999 1

START-UP Fill the Gear Box with lubricating oil, before and until the oil flows out of oil check port on the Cover. After confirming the sufficient oil level, tighten each plugs of the port. Air and water must be purged from the hydraulic system, otherwise the hydraulic components will be subject to failure from cavitation or lack of lubrication. The motor may be purged by operating for a while under no load with low speed. Check also that no air bubbles are present in the reservoir before beginning the operation. Make sure all connections are tight.

PERIODIC MAINTENANCE

REPLACE SEALS Replace all seals in the motor section, if the accumulated operation period with the fluid temperature over 80℃ (176F) is reached 100 hours. Replace all seals in the Gear Box, if the accumulated operation period with the oil temperature over 90℃ (194F) is reached 100 hours. HYDRAULIC FUID Initial Replacement 500 Hr. Visual Inspection Every 500 Hr. Performance Inspection Every 1000 Hr. HYDRAULIC FILTER Initial Replacement 50 Hr. Periodic Replacement Every 250 Hr. LUBRICATING OIL Initial Replacement 100 ~ 250 Hr. Performance Inspection Every 1000 Hr. Periodic Replacement Every 1000 ~ 1500 Hr. MOTOR SECTION Internal Inspection and Seals Replacement

Every 1000 Hr. Brake Disk Replacement Every 300,000 cycle

SERVICE INFORMATION

PREPARATION Before removing the motor from the installation, drain all oil inside, then cover the oil port area to prevent foreign particles from entering the motor. Before disassembling the motor, clean outside of the motor thoroughly. During disassembling, warn the parts to protect from damage. DISASSEMBLY PROCEDURE 1. Base Plate (a) Position the motor with the piston motor side up. Loosen

the Socket Head Bolts (102-6-4) evenly. Remove the Flange (102-6-1), Spring Seat (102-5), Spring (102-4) and Spring Seat (102-3).

(b) While turning, pull the Plunger Assy (102-2) out. If difficulty is encountered, tap the end of the Plunger and insert it. Be sure the Plunger slides smoothly and then

try again. Do not disassemble the Plunger Assy. (c) Remove the Relief Valve Assy (102-7), loosening the

Plug (102-7-6). Do not loosen the Nut (102-7-16) and Set Screw (102-7-15). The setting pressure is changed by loosening the Nut and Set Screw. The Poppet Seat (102-7-3) will be remained in the Base Plate. Remove the Poppet Seat.

(d) Remove the Plugs (102-17) and the Spring (102-13). While turning, pull the Spool (102-9) out. If difficulty is encountered, Tap the end of the Spool and insert it. Be sure the Spool slides smoothly, then try again.

(e) Do not loosen the Plugs (102-8) and the Orifices (102-23) (102-22) if it is not necessary.

(f) Loosen the Socket Head Bolts (300) evenly and pull the assembly of the Case (101) and Base Plate (102-1) out of the Flange (210). If difficulty is encountered, tap the top of the Base Plate (102-1) and insert it, then try again.

(g) Position the assembly of the Case and Base Plate Assy with shaft down. Loosen the Socket Head Bolts (120) evenly and remove the Base Plate (102-1) away with the caution not to have the Pins (128) stick.

(h) Remove the Valve Plate (105), the Springs (129) (149), the O-Ring (122) (133) and the Pin (118) (128). Care must be taken during the process not damage the Valve Plate.

2. Brake Piston (a) Blow compressed air to the oil passage of the brake to

remove the Brake Piston (125) from the Case. Pay full attention the Brake Piston may be ejected out.

(b) Remove the O-Rings (130) (131) from the Brake Piston. Remove the Disk Plate (127) and Friction Plate (126).

3. Cylinder Block (a) Pull the Cylinder Block Assembly (104) (106) (107)

(108) (114) (115) (116) (117) (119) out by holding the Retainer Plate (107) and the Cylinder Block. Care must be taken during the process not damage the Piston Shoe and Cylinder Block.

(b) Mark the Piston Assy and Cylinder Block to identify the each position. Remove the Piston Assy (106) and Retainer Plate (107) from the Cylinder Block (104).

(c) Remove the Retainer Holder (108) and Pins (119). (d) Press the Spring, using the press machine. Use a Snap

Ring Pliers to remove the Snap Ring (114). Remove the Collar (115) (117) and the Spring (116) from the Cylinder Block.

4. Remove the Swash Plate (109). 5. Remove the Steel Balls (110), the Piston Assy (111)

and the Spring (139) from the Case. The Steel Ball may be come with Swash Plate.

6. Remove the Shaft (103), the Ball Bearing (112)and the Oil Seal (121).

7. Gear Box (a) Remove the Plugs(226) and Drain the lubrication oil in

the Gear Box. (b) Remove the Socket Head Bolts (208) and the Cover

(224). Tap the Cover using plastic hammer to remove the Cover, because the Cover is sealed by liquid gasket.

(c) Remove the Thrust Plate(s) (223). (d) Remove the Drive Gear (204) and the Holder A S/A

(201). (e) Remove the Thrust Plate (205) and the Sun Gear B


06/25/1999 2

(206). (f) Remove the Holder B S/A (202) and the Sun Gear C

(208). (i) Loosen the Socket Head Bolts (221) evenly and remove

the Ring Gear (219) with the caution not to have the Pins (222) stick.

(g) Loosen the Socket Head Bolts (216) (217) and remove the Plate (218). Using a press, remove the Holder C S/A (203) with the caution not to have the Pins (215) stick. Remove the Shim (214).

(h) Remove the Coupling (600). (i) Press the Flange (210) out of the Housing (213). (j) Using (-) screwdriver remove the Floating Seal (211)

from the Housing. (k) Press the Angular Bearings (212) out of the Housing. (l) Using (-) screwdriver remove the another Floating Seal

(211) from the Flange. After disassembly, wash the parts with cleaning solvent. Sufficient rust prevention is necessary to store the parts. ASSEMBLY PROCEDURE All parts must be thoroughly cleared and ensured there is no dust, damage or scratch prior to assembly. Seals and bearings must be replaced with new one. 1. Gear Box (a) Grease fully the Floating seals (211). Put the one of

Floating Seal (211) into the Flange (210). (b) Put the other Floating Seal on the Floating seal already

set on the Flange. Ensure the concentricity of these Floating Seals.

(c) Press the inner race of the Angular Bearing (212) into the Flange (210).

(d) Press the outer races of both Angular Bearings into the Housing (213) from both sides.

(e) Put the Housing (213) on the Flange (210) quietly. (f) Press the inner race of the Angular Bearing remaining

into the Flange (210). (g) Press the top of the inner race of the Angular Bearing

(212) already installed into the Flange (210) with even thrust force of 3000kgf. While pressing, measure the gap ( H ).

(h) Measure the gap ( h ) on the bottom surface of the Holder C S/A (203).

t > h - H t : Thickness of the Shim(s) (i) Calculate the shim thickness required ( t ). (j) The Shim(s) (214) may be combined in order to assure

that Height of the Shim(s) ( t ) is slightly greater than h - H.

(k) Press the Pins (215) into the Flange (210) so that the

Pins project from the Flange by 26.5 – 27.5 mm. (l) Grease the Shim(s) (214) and put it on the bottom

surface of the Holder C S/A (203). (m) Put the Holder C S/A (203) onto the Flange (210). The

pins must be properly inserted into the Flange. (n) Apply “Locktite No. 271” on the thread surface of the

Socket Head Bolts (216) and then evenly tighten them into the flange (210).

(o) Tap the Pins (222) on the Housing (213) so that the Pins project from the top surface of the Flange by 17mm.

(p) Put the O-Ring (220) into the Housing (213). (q) Put the Ring Gear (219) onto the Housing (213). Tighten

the Socket Head Bolts (221) evenly. (r) Ensure the Snap Rings (209) and (207) are properly

installed into the Sun Gear C (208) and Sun Gear B (206). Put the Sun Gear C into the Holder C S/A (203) and put the Holder B S/A (202) onto the Sun Gear C (208) and then put the Sun Gear B (206) into the Holder B S/A (202).

(s) Grease the Thrust Plate (205) and put it on the bottom surface of the Holder A S/A (201).

(t) Put the Holder A S/A (201) onto the Sun Gear B (206). (u) Put the Drive Gear (204) into the Sun Gears B and C.

The Drive Gear must be properly engaged with the planetary gears of the Holder A S/A (201).

(v) Measure the gap ( Hr ). Referring to the table-1below, choose the appropriate Thrust Plate (223) according to the gap ( Hr ) and put it onto the Drive Gear (204).

Gap ( Hr ) Thrust Plate ( 223 ) 1.74 to 1.21 20941-62305 1.20 to 0.67 20941-62306 0.66 to 0.04 20941-62307 0.03 to -0.16 20941-62308 -0.17 to –0.41 20941-62309

table-1 (w) Degrease the contact surface of the Ring Gear (219)

and the Cover (224). Apply uniformly the liquid gasket, “Three Bond 211” and then put the Cover onto the Ring Gear. Tighten the Socket Head Bolts (225).

(x) Tighten the Plugs (226) using Teflon tape. (y) Position the Gear Box with the piston motor side up.

Degrease the thread surface of the Socket Head Bolts (217) and thread hole of the Flange (210). Apply “ Locktite No.217” on the thread surface of the Socket Head bolts. Put the Plates (218) into the Flange (210) and tighten the Socket Head Bolts (217).

(z) Ensure the Pin (601) is completely inserted into the Coupling (600) and put the coupling onto the spline shaft of the Drive Gear (204).

H

h

Holder C S/A (203)

Housing (213)

Flange (210)

t

Shim(s) (214)

Hr

Holder A S/A (201) Ring Gear

(219)


06/25/1999 3

2. Motor Section (a) Apply grease on the Oil Seal (121). Press into the Case

(101). Ensure the Oil Seal was completely installed. (b) Place the Springs (139) into the bores at the bottom of

the Case (101). Apply grease on the sliding surfaces of the Piston Assys (111) and insert into the bores.

(c) Press the Ball Bearing (112) onto the Shaft (103). Insert the Shaft into the Case (101). Ensure the Shaft rotates smoothly.

(d) Apply working fluid on the Steel Balls (110) and the spherical hollows at the bottom of the Case (101). Place the Steel Balls into the hollows and the Swash Plate (109) into the Case (101).

(e) Place the Spring Seat (115), the Spring (116) and the Collar (117) into the Cylinder Block (104). Press the Spring and install the Snap Ring (114).

(f) Apply grease on the Pins (119) and insert the Pins into the Cylinder Block (104). Place the Retainer Holder (108) onto the Cylinder Block.

(g) Put all the Piston Assy (106) into the Retainer Plate (107) from the flat surface of the Retainer Plate.

(h) Apply the hydraulic fluid in the bores of the Cylinder Block (104) and on the spherical surface of the Retainer Holder (108). Insert the Piston Assys into the Cylinder Block.

(i) Apply the hydraulic fluid on the sliding surface of the Swash Plate (109) and the sliding surfaces of the shoes of the Piston Assys. Insert the Cylinder Block Assembly onto the Shaft (103).

(j) Submerge the Disk Plate (127) in the hydraulic fluid prior to the assembly. Place the Disk Plates and the Friction Plate (126) into the Case (101).

(k) Fit the D-Rings (130) (131) into the grooves of the Brake Piston (125) and apply grease on the sliding surface. Insert the Brake Piston into the Case so that the holes for the pins on the Brake Piston and Case align.

(l) Put the Springs (141) and (129) onto the Brake Piston. 3. Base Plate (a) Press the Ball Bearing (113) into the Base Plate (102). (b) Insert the Pin (118) into the Valve Plate (105). (c) Apply grease to the back of the Valve Plate. Place the

Valve Plate onto the Base Plate with the bronze color side up.

(d) Apply grease on the O-Ring (122) and place it onto the Case (101).

(e) Place the O-Rings (133) onto the Case (101) without grease. Insert the Pins (128) into the Base Plate (102) with tapered side up.

(f) Place the Base Plate (102) onto the Case (101) with caution that any parts under the Base Plate should not drop. Tighten the Socket Head Bolts (120) and (300).

(g) Insert the Spool (102-9) ,Spring (102-13) and Spring Guide (102-16) into the Base Plate(102). Ensure the O-Rings (102-15) are installed into the Plugs (102-14) and (102-17), tighten the Plugs into the Base Plate.

(h) Make sure that there is the Poppet Seat (102-7-3) at the top of the Relief Valve. Apply grease onto the O-Rings of the Relief Valve. Insert the Relief Valve Assy (102-7) into the Base Plate (102) and Tighten.

(i) Insert the Plunger Assy (102-2) into the Base Plate (102). Place the Spring Seat (102-3), Spring (102-4), and another Spring Seat (102-5) onto each side of

Plunger Assy. Ensure the O-Ring (102-6-2) is put into the groove on the Cap Assy (102-6). Put both Caps (102-6) to the Base Plate (102) and tighten the Socket Head Bolts (102-6-4).


06/25/1999 4

CRITERION REPLACEMENT Replace parts in the following criterion when disassembling the motor. Handle each of parts with deliberation and take care not to damage them. Replace all seals when disassembling the motor, even though no damage is found on them. Hydraulic Motor Section

Item & Check Point Allowable Limit Parts to be Replaced Piston Assy (106) (a) Deep score or roughness on the shoe. (b) Deep score or roughness on the reciprocating potion. (c) Large clearance between the Piston and Cylinder Block. (d) Play on the shoe ball portion.

0.8a 1.2a 0.060mm 0.40mm

Cylinder Block Kit (B6)

Cylinder Block (104) (a) Deep score or roughness on the sliding portion. (b) Deep score or roughness inside bore. (c) Large clearance between the Piston. (d) Large clearance between the Shaft spline.

0.8a 1.6a 0.060mm 38.749(pin dia.3.333)

Cylinder Block Kit (B6)

Valve Plate (105) (a) Roughness of the sliding portion or deep score caused by

serious damage, seizure and partial wear.

0.8a <0.02mm(scoring depth)

Valve Plate (105)

Retainer Plate (107) Retainer Holder (108) (a) Roughness of the sliding portion or deep score caused by

serious damage, seizure and partial wear.


Retainer Plate (107) Retainer Holder (108)

Swash Plate (109) (a) Roughness of the sliding portion or deep score caused by

serious damage, seizure and partial wear. (b) Deep score or roughness on the Steel Ball portion. (c) Depth of the Steel Ball portion.

0.8a <0.02mm(scoring depth) 1.6a 14.5mm

Swash Plate (109) Steel Ball (110) if it is necessary.

Shaft (103) (a) Deep lip mark, roughness or serious damage on the sliding

portion for Oil Seal. (b) Excessive wear or breakage on the spline (c) Large clearance between the Cylinder Block spline hole. (d) Large clearance between the Coupling spline hole.

1.6a <0.02mm(scoring depth) 47.380(pin dia.3.000 30.498(pin dia.3.33)

Shaft (103)

Brake Piston (125) (a) Dimension (b) Roughness or serious damage on the sliding portion.

45. 7mm (Height) 2.5a

Brake Kit (125)

Disk Plate (127) (a) Dimension (b) Serious damage or peeling.

3.2 (Thickness)

Brake Kit (127)

Ball Bearing (112), (113) (a) Serious damage on the races and Balls. (b) Discontinuous rotation

Ball Bearing (112), (113)

Piston Assy (111) (a) Deep score or roughness on the shoe. (b) Deep score or roughness on the reciprocating potion. (c) Large clearance between the Piston and Flange Holder. (d) Play on the shoe ball portion.

1.6a 1.2a 0.040mm 1.0mm

Case Kit (B7)

Plunger Assy (102-2) (a) Serious damage, roughness or deep score. (b) Large clearance between the Plunger and bore.

0.8a <0.02mm(scoring depth) 0.060mm

Base Plate Kit (B5)

Base Plate (102) (a) Serious damage, roughness or deep score on the bore.


Base Plate Kit (B5)

Spool (102-9) (a) Serious damage, roughness or deep score. (b) Large clearance between the Spool and bore.

0.8a 0.060mm

Base Plate Kit (B5)

Relief Valve Assy (102-7) (a) Roughness or serious damage on the Free Piston sliding

<0.02mm(scoring depth) Relief Valve Assy (B4)


06/25/1999 5

portion or the Poppet seating portion.


06/25/1999 6


06/25/1999 7


06/25/1999 8

�0 • Engine Air Cleaners, Accessories & Service Parts

MED

IUM

DU

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FKB Air Cleaner

www.donaldson.com/aircleaners

The FKB family of two-stage air cleaners for medium dust conditions.

Compared to other air cleaner styles, this new air cleaner family delivers the performance of competitive larger air cleaners in a compact, rugged design.

With a heavy-duty plastic construction and non-metal filters, the air cleaner is lighter, more efficient and easier to install and replace than competing products.

Another key design feature is the built-in mounting brackets. There's no need for additional mounting support.

The two stage design features a built-in pre-cleaner that separates up to 85% of airborne contaminants.

Smaller, Lightweight Alternative Two-Stage Air CleanerDesigned for horizontal installation

Donaldson FKB air cleaners are protected internationally by patents, trademarks, and design registrations, both issued and pending.

The FKB’s plastic housing and durable construction enables its installation in all types of operating environments and temperature ranges from -40° to 82°C, operating in medium-dust conditions with engine air flow from 70 to 360 cfm.

FKB0�

FKB0�

FKB0�

FKB06

FKB air cleaners effectively reduce contaminants flowing into the air intake system, provide a high level of engine protection from harmful contaminants and increase engine performance and fuel efficiency.

The air cleaner models ship with both the primary and safety filters.

Mann & Hummel Donaldson FKB0� Fleetguard/Nelson

FKB air cleaners are smaller in diameter compared to competitive brands with similar airflow.

Engine Air Cleaners, Accessories & Service Parts • ��

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FKB Air Cleaner


Built-in Mounting Brackets and Filter Indicator PortEasy to service with non-metal filters

Applications• Off-road equipment operating in

medium-dust conditions with engine airflow range of 70 to 360 cfm (2 to 10.3 m3/min)

• Installs horizontally. Mounting the air cleaner directly to the engine is not recommended; excessive engine vibration can cause premature air cleaner structural failure

• Sustained temperature tolerance: -40º to 180°F / -40º to 82°C. Do not install next to components that exceed the maximum temperature (180ºF / 82ºC); like a turbocharger, muffler, exhaust pipe or other high temperature component

Features• Smaller in diameter compared to

competitive brands with similar airflow

• Improved handling and maintenance: lighter and smaller, changing filters is a snap

• Product design includes: - primary filter - safety filter - filter service indicator port

• Improved filter disposal ease: no metal

• Cover latch position allows for minimum service clearance and eases filter service

• Mounting brackets built-in to air cleaner body eliminating need for mounting bands

Inlet

Filter changeout is a snap with minimal service clearance required

Outlet

Picture of the B080074 filters next to the B045008 model filters - each set is shipped with the air cleaner.

�� • Engine Air Cleaners, Accessories & Service Parts

MED

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FKB Air Cleaner


When spec’ing an Air Cleaner . . .Determine the airflow requirements of your engine, then find the corresponding cfm airflow in the table at right. The restriction numbers (shown in inches of water) indicate the approximate initial restriction of each model air cleaner at that cfm. If there are two air cleaner models that fit your parameters, choosing the one with the lowest restriction will provide longest filter service life. When calculating total initial restriction of the entire air intake system, include the restriction caused by ducting, elbows, pre-cleaners, etc.

FKB Specification Illustrations

Initial Airflow Restriction

CFM Air Cleaner6" H�O �" H�O �0" H�O Model

70 84 95 B045008 116 137 154 B055006 155 185 207 B065045

265 315 360 B080074

Airflow Pattern “B”Air in the side, out the end

FKB Specifications

Body Inlet Outlet Housing Inlet Outlet Inlet Center Service Restr. MountingAir Cleaner Dia. Dia. Dia. Length Height Length Loca- Line to Clear. Tap BracketModels (A) (B) (C) (D) (E) (F) tion (G) Valve (H) (I) Weight Loc. (J) Height (K)

B045008 5.22" 2.00" 2.00" 13.46" 3.88" 2.83" 1.60" 6.18" 7.44" 2.1 lb 2.02" 2.82" 133mm 51mm 51mm 342mm 99mm 72mm 41mm 157mm 189mm 1.0 kg 52mm 72mmB055006 5.97" 2.50" 2.50" 15.89" 3.88" 2.88" 1.93" 6.18" 9.61" 3.2 lb 2.05" 3.03" 152mm 64mm 64mm 404mm 99mm 73mm 49mm 157mm 244mm 1.4 kg 52mm 77mmB065045 7.09" 3.00" 3.00" 16.06" 4.72" 2.87" 2.07" 7.41" 9.50" 3.7 lb 2.05" 3.54" 180mm 76mm 76mm 408mm 120mm 73mm 53mm 188mm 241mm 1.7 kg 52mm 90mmB080074 8.95" 4.00" 4.00" 16.75" 5.50" 2.40" 2.68" 7.78" 14.76" 5.52 lb 1.57" 4.33" 227mm 102mm 102mm 425mm 140mm 61mm 68mm 198mm 375mm 2.5 kg 40mm 110mm

E

AK

C

I

B

H

M8 X 1.25

(2 - B04,B05 and B06)

(4 - B080074)

D

F

G

EJ

A

Cover End View -B080074 Cover End View for B04, B05, and B06

K

M8 X 1.25

Side View

J

Engine Air Cleaners, Accessories & Service Parts • �3

MED

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FKB Air Cleaner


Vacuator™ ValveBuilt-in Mounting Bracket

Cover latch position requires minimum space requirement for filter service

Primary FilterSafety Filter inside

Filter Service Indicator Port

Plastic Housing

Service Cover

FKB Service Parts

B0��00�cover ................................................. P606497filter, primary .................................... P604457filter, safety ....................................... P603729Vacuator™ Valve ............................. P158914

B0��006cover ................................................. P609219filter, primary .................................... P609218filter, safety ....................................... P602427Vacuator™ Valve ............................. P158914

Air Inlet

Outlet to Engine

Safety Filter

B06�0��cover ................................................. P608592filter, primary .................................... P609221filter, safety ....................................... P608599Vacuator™ Valve ............................. P158914

B0�00��cover ................................................. P605731filter, primary (metal liner) ............. P611190filter, safety ....................................... P611189Vacuator™ Valve ............................. P158914

�� • Engine Air Cleaners, Accessories & Service Parts

MED

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� Install the new filterInstall new filter. On FKB04, 05 and 06 models, press and rotate filter clockwise until fully engaged to stop. For the FKB08 radial seal filter, push straight in until seated firmly.

� Replace the coverReplace the service cover. The “INLET” arrow should line up with the air cleaner inlet. DO NOT force cover onto air cleaner. The cover should go on with no extra force. If cover is not flush to the body, the filter is not properly seated in the housing.

9 Refasten the latchesRefasten latches to secure cover. Make sure that latches penetrate the slots in both the body and the cover.

�0 InspectInspect and torque all clamps, bolts and connections in the entire air intake system. Check for holes in piping, and repair if needed. If Vacuator Valve is damaged replace.

�� Restart the engine

� Shut off your engine

� Remove service coverUnlatch and remove the service cover. To remove the primary filter on FKB04, 05 and 06 models, press and rotate filter counterclockwise until filter is free. The FKB08 primary filter is a radial seal design, gently move the end of the filter back and forth to break the seal.

3 Remove the filterGently pull the filter out of housing. Avoid dislodging contaminant from the filter or knocking it against the housing.

� Clean the inside surfaceWith a soft rag, thoroughly clean the inside surface of the housing. Be careful not to introduce contaminant into the outlet tube.

� Check the safety filterCheck safety filter for damage. If damaged, replace. Also check to insure that the safety filter is properly seated in the housing. It should fit snugly inside the outlet tube.

6 Inspect the new primary filterInspect the new primary filter carefully. Check for any voids, cuts, tears or indentations in the urethane-sealing surfaces.

Recommended Maintenance Procedures

Installation Recommendations• Shut off your engine.

• Air cleaner orientation is horizontal, with the drop tube pointing down - within +/- 15º. For service clearance, allow the entire length of the filter for removal and 35mm for service cover latches.

• Mounting is M8 x 1.25, with a maximum torque of 15 ft. lbs.

• Connections: Inlet/Outlet maximum torque 40 in. lbs. Indicator port maximum torque 1.5 ft. lbs.

• Inlet accessory note: The air cleaner housing can accommodate a lightweight inlet hood, but not a pre-cleaner or any other accessory. Use of an unapproved intake accessory will void your Donaldson warranty.

FKB Service Instructions